Chevrolet - Cruze - Workshop Manual - 2011 - 2011

Factory Workshop Manual Make Chevrolet Model Cruze Engine and year L4-1.4L Turbo (2011) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Relay > Component Information > Locations Accessory Relay: Locations Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Relay > Component Information > Locations > Page 7 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 11 Alarm Module: Diagrams Component Connector End Views K89 Immobilizer Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 12 Alarm Module: Service and Repair Theft Deterrent Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Locations Communications Control Module: Locations Instrument Panel/Center Console Component Views Behind the Right Side of the I/P Components 1 of 2 1 - F105 Passenger Instrument Panel Air Bag 2 - K82 Mobile Telephone Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement Communications Control Module: Service and Repair Communication Interface Module Replacement Communication Interface Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement > Page 18 Communications Control Module: Service and Repair Communication Interface Module Battery Replacement Communication Interface Module Battery Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement > Page 19 Communications Control Module: Service and Repair Communication Interface Module Bracket Replacement Communication Interface Module Bracket Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement > Page 20 Communications Control Module: Service and Repair Mobile Telephone Control Module Replacement Mobile Telephone Control Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 29 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 35 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams Entertainment System Control Module: Diagrams Component Connector End Views T11 Multimedia Interface Module (KTA) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Page 39 Entertainment System Control Module: Service and Repair Multimedia Player Interface Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Passenger Compartment/Roof Component Views Roof/Headliner Components 1 - B160 Windshield Temperature and Inside Moisture Sensor 2 - K84 Remote Function Receiver Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations Parking Assist Control Module: Locations Luggage Compartment/Rear of Vehicle Component Views Left Side of the Luggage Compartment Components 1 - X2 Parking Assist Control Module X2 2 - X1 Parking Assist Control Module X1 3 - K41 Parking Assist Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 46 Parking Assist Control Module: Diagrams Component Connector End Views K41 Parking Assist Control Module X1 (UD7) K41 Parking Assist Control Module X2 (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 47 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 48 Parking Assist Control Module: Service and Repair Rear Object Alarm Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 57 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 58 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 59 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 65 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 66 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 67 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Passenger Compartment/Roof Component Views Roof/Headliner Components 1 - B160 Windshield Temperature and Inside Moisture Sensor 2 - K84 Remote Function Receiver Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams Seat Heater Control Module: Diagrams Component Connector End Views K29 Seat Heating Control Module X2 (KA1) K29 Seat Heating Control Module X3 (KA1) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 75 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 76 Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations Sunroof / Moonroof Module: Locations Passenger Compartment/Roof Component Views Overhead Console Components 1 - S72 Sunroof Switch 2 - S88 Sunroof Ventilation Switch 3 - E37B Dome / Reading Lamps - 2nd Row 4 - K61 Sunroof Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 80 Sunroof / Moonroof Module: Diagrams Component Connector End Views K61 Sunroof Control Module (CF5) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trunk / Liftgate Relay > Component Information > Locations Trunk / Liftgate Relay: Locations Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trunk / Liftgate Relay > Component Information > Locations > Page 84 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - K17 Electronic Brake Control Module (EBCM) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 89 Electronic Brake Control Module: Diagrams Component Connector End Views K17 Electronic Brake Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 90 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module Replacement (MK60 EC) Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement (MK60 EC) Electronic Brake Control Module Replacement (MK60 EC) Removal Procedure The electronic brake control module may not be replaced singly. Always replace control module in assemble with brake pressure modulator valve. Refer to Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake Pressure Modulator Valve Replacement). Installation Procedure The electronic brake control module may not be replaced singly. Always replace control module in assemble with brake pressure modulator valve. Refer to Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake Pressure Modulator Valve Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module Replacement (MK60 EC) > Page 93 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement (MK60 P) Electronic Brake Control Module Replacement (MK60 P) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module Replacement (MK60 EC) > Page 94 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 99 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 100 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 101 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 106 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 107 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 108 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations Control Module HVAC: Locations Instrument Panel/Center Console Component Views Behind the Center of the I/P Components (C68) 1 - X212 Instrument Panel Harness and HVAC Haness 2 - X3 HVAC Control Module X3 3 - K33 HVAC Control Module 4 - X2 Blower Motor Control Module X2 5 - K8 Blower Motor Control Module 6 - M8 Blower Motor 7 - X1 Blower Motor Control Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 112 Control Module HVAC: Diagrams Component Connector End Views K8 Blower Motor Control Module X1 K8 Blower Motor Control Module X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 113 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic Control Module HVAC: Service and Repair HVAC - Automatic Heater and Blower and Air Conditioning Control Module Replacement (Left Hand Drive) Removal Procedure 1. Remove instrument panel compartment. Refer to Instrument Panel Compartment Replacement (See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Compartment Replacement). 2. Remove floor air outlet duct right side. Refer to Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive) (See: Heating and Air Conditioning/Air Duct/Service and Repair/Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive)). 3. Remove the 2 heater and blower and air conditioning control module bolts (1) and the heater and blower and air conditioning control module wiring harness plug (2). 4. Remove heater and blower and air conditioning control module (3). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 116 1. Install heater and blower and air conditioning control module (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the heater and blower and air conditioning control module wiring harness plug (2) and the 2 heater and blower and air conditioning control module bolts (1). Tighten to 2.5 Nm (23 lb in). 3. Install floor air outlet duct - right side. Refer to Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive) (See: Heating and Air Conditioning/Air Duct/Service and Repair/Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive)). 4. Install instrument panel compartment. Refer to Instrument Panel Compartment Replacement (See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Compartment Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 117 Control Module HVAC: Service and Repair HVAC - Manual Heater and Blower and Air Conditioning Control Module Replacement (Left Hand Drive) Removal Procedure 1. Remove instrument panel compartment. Refer to Instrument Panel Compartment Replacement (See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Compartment Replacement). 2. Remove floor air outlet duct right side. Refer to Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive) (See: Heating and Air Conditioning/Air Duct/Service and Repair/Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive)). 3. Remove the 2 heater and blower and air conditioning control module bolts (1) and the heater and blower and air conditioning control module wiring harness plug (2). 4. Remove heater and blower control module (3). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 118 1. Install heater and blower control module (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the heater and blower and air conditioning control module wiring harness plug (2) and the 2 heater and blower and air conditioning control module bolts (1). Tighten to 2.5 Nm (22 lb in). 3. Install floor air outlet duct right side. Refer to Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive) (See: Heating and Air Conditioning/Air Duct/Service and Repair/Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive)). 4. Install instrument panel compartment. Refer to Instrument Panel Compartment Replacement (See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Compartment Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 123 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 124 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 125 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations High Beam Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 129 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 130 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 131 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 135 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 136 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 137 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Tail Lamp Control Module > Component Information > Service and Repair Tail Lamp Control Module: Service and Repair Tail Lamp Control Module with Bulb Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Accessory Relay > Component Information > Locations Accessory Relay: Locations Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Accessory Relay > Component Information > Locations > Page 145 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations/A - Z Index) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 150 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID) to locate the electrical center where the relay exists. Note: * Always note the orientation of the relay. * If equipped with a notch style relay; observe the location of the notch on the old relay to verify the new relay is installed with the notch in the same location. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 151 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery Relay Box: Application and ID Fuse Block - Battery Electrical Center Identification Views X50D Fuse Block - Battery Auxiliary Top View X50D Fuse Block - Battery Auxiliary Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 156 X50D Fuse Block - Battery Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 157 X50D Fuse Block - Battery Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 158 X50D Fuse Block - Battery X3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 159 X50D Fuse Block - Battery X4 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 160 X50D Fuse Block - Battery X6 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 161 Relay Box: Application and ID Fuse Block - Underhood Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 162 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 163 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 164 X50A Fuse Block - Underhood Bottom View X50A Fuse Block - Underhood Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 165 X50A Fuse Block - Underhood X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 166 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 167 X50A Fuse Block - Underhood X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 168 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 169 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 170 X50B Fuse Block - Underhood Auxiliary X8 X50B Fuse Block - Underhood Auxiliary X9 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 171 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 172 Relay Box: Application and ID Fuse Block - Instrument Panel Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 173 X51A Fuse Block - Instrument Panel (Fuses) Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 174 X51A Fuse Block - Instrument Panel (Relays) Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 175 X51A Fuse Block - Instrument Panel Bottom View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 176 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Recalls for Body Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Body Control Module: Recalls Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Recalls for Body Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 187 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Recalls for Body Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 188 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Body Control Module: All Technical Service Bulletins Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 194 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 195 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 196 Body Control Module: Locations Instrument Panel/Center Console Component Views Behind the Center of the I/P Components 1 of 4 1 - K9 Body Control Module 2 - X7 Body Control Module X7 3 - X6 Body Control Module X6 4 - X5 Body Control Module X5 5 - X4 Body Control Module X4 6 - X3 Body Control Module X3 7 - X2 Body Control Module X2 8 - X1 Body Control Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 197 Body Control Module: Diagrams Component Connector End Views K9 Body Control Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 198 K9 Body Control Module X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 199 K9 Body Control Module X3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 200 K9 Body Control Module X4 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 201 K9 Body Control Module X5 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 202 K9 Body Control Module X6 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 203 K9 Body Control Module X7 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 204 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Body Control Module Replacement Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Body Control Module Replacement > Page 207 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues Engine Control Module: Recalls Campaign - Thermostat Sticks Open Causes Shift Issues SERVICE UPDATE Bulletin No.: 10399A Date: December 02, 2010 Subject: 10399A - Service Update for Inventory and Customer Vehicles - Powertrain Improvements - Thermostat Sticks in Open Position and Shift Quality - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with a 1.4L Turbo Engine (LUJ) Supercede: The Subject and Purpose in this bulletin are being revised to advise that the new ECM calibration will also address shift quality issues.Please discard all copies of bulletin 10399, issued November 2010. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to reprogram the engine control module (ECM) on certain 2011 model year Chevrolet Cruze vehicles equipped with a 1.4L turbo engine (LUJ). These vehicles may have a condition where the thermostat sticks in the open position. If this occurs, diagnostic codes will be set and the Service Vehicle Soon light/message will illuminate. These vehicles may also have transmission shift quality issues due to calibration values. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. Additionally, a list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should also be checked for vehicle eligibility. Parts Information No parts are required for this update. Service Procedure Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 11/29/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming. 2. Reprogram the engine control module (ECM) and transmission control module (TCM) in sequence. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI or Tech 2(R) to the vehicle. If using MDI, connect to programming terminal with the cable (USB or LAN). 2. Select J-2534 MDI or J-2534 Tech 2(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues > Page 216 3. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. 4. Follow the on-screen instructions. 3. Clear all DTCs using the GDS or Tech 2(R). Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Engine Control Module: Recalls Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 221 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 222 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues Engine Control Module: All Technical Service Bulletins Campaign - Thermostat Sticks Open Causes Shift Issues SERVICE UPDATE Bulletin No.: 10399A Date: December 02, 2010 Subject: 10399A - Service Update for Inventory and Customer Vehicles - Powertrain Improvements - Thermostat Sticks in Open Position and Shift Quality - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with a 1.4L Turbo Engine (LUJ) Supercede: The Subject and Purpose in this bulletin are being revised to advise that the new ECM calibration will also address shift quality issues.Please discard all copies of bulletin 10399, issued November 2010. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to reprogram the engine control module (ECM) on certain 2011 model year Chevrolet Cruze vehicles equipped with a 1.4L turbo engine (LUJ). These vehicles may have a condition where the thermostat sticks in the open position. If this occurs, diagnostic codes will be set and the Service Vehicle Soon light/message will illuminate. These vehicles may also have transmission shift quality issues due to calibration values. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. Additionally, a list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should also be checked for vehicle eligibility. Parts Information No parts are required for this update. Service Procedure Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 11/29/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming. 2. Reprogram the engine control module (ECM) and transmission control module (TCM) in sequence. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI or Tech 2(R) to the vehicle. If using MDI, connect to programming terminal with the cable (USB or LAN). 2. Select J-2534 MDI or J-2534 Tech 2(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues > Page 228 3. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. 4. Follow the on-screen instructions. 3. Clear all DTCs using the GDS or Tech 2(R). Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 233 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Engine Control Module: All Technical Service Bulletins Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 238 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 239 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 244 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 245 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 246 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 252 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 257 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 258 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 259 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 260 Engine Control Module: Description and Operation Engine Control Module Description The engine control module (ECM) interacts with many emission related components and systems, and monitors the emission related components and systems for deterioration. OBD II diagnostics monitor the system performance and a diagnostic trouble code (DTC) sets if the system performance degrades. The malfunction indicator lamp (MIL) operation and the DTC storage are dictated by the DTC type. A DTC is ranked as a type A or type B if the DTC is emissions related. Type C is a non emissions related DTC. The ECM is located in the engine compartment. The ECM is the control center of the engine controls system. The ECM controls the following components: * The fuel injection system * The ignition system * The emission control systems * The on-board diagnostics * The A/C and fan systems * The throttle body motor system The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect the vehicle performance and the emissions. The ECM also performs diagnostic tests on various parts of the system. The ECM can recognize operational conditions and alert the driver via the MIL. When the ECM detects a malfunction, the ECM stores a DTC. The condition area is identified by the particular DTC that is set. This helps the technician in making repairs. ECM Function The engine control module (ECM) can supply 5 V or 12 V to the various sensors or switches. This is done through pull-up resistors to the regulated power supplies within the ECM. In some cases, even an ordinary shop voltmeter will not give an accurate reading because the resistance is too low. Therefore, a DMM with at least 10 Mohm input impedance is required in order to ensure accurate voltage readings. The ECM controls the output circuits by controlling the ground or the power feed circuit through the transistors or a device called an output driver module. EEPROM The programmable read only memory (EEPROM), which can be erased electronically, is a permanent memory that is physically part of the engine control module (ECM). The EEPROM contains program and calibration information that the ECM needs in order to control the powertrain operation. Special equipment, as well as the correct program and calibration for the vehicle, are required in order to reprogram the ECM. ECM Default Actions When a malfunction occurs within the engine control system, the engine control module (ECM) maintains control of the system with default actions. Default actions are calculated values, and/or calibrated default values, that are stored within the ECM. A certain level of engine performance is possible when a malfunction occurs dependant on the default actions taken. The ECM default actions prevent a complete loss of engine performance. ECM Output Controls The scan tool can control certain solenoids, valves, motors, and relays. The output controls can be found under the special functions selection of the scan tool. Some output controls may be disabled by the engine control module (ECM) during certain types of vehicle operation. Data Link Connector (DLC) The data link connector (DLC) is a 16-pin connector that provides the technician with a means of accessing serial data for aid in the diagnosis. This connector allows the technician to use a scan tool in order to monitor the various serial data parameters, and display the DTC information. The DLC is located inside the drivers compartment, underneath the dash. Malfunction Indicator Lamp (MIL) The malfunction indicator lamp (MIL) is located on the instrument panel cluster, or the driver information center. The MIL is controlled by the engine control module (ECM) and illuminates when the ECM detects a condition that affects the vehicle emissions. ECM Service Precautions Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 261 The engine control module (ECM), by design, can withstand the normal current draws that are associated with the vehicle operations. However, care must be taken in order to avoid overloading any of these circuits. When testing for opens or shorts, do not ground or apply voltage to any of the ECM circuits unless the diagnostic procedure instructs you to do so. These circuits should only be tested with a DMM. Aftermarket (Add-On) Electrical And Vacuum Equipment Caution: Do not attach add-on vacuum operated equipment to this vehicle. The use of add-on vacuum equipment may result in damage to vehicle components or systems. Caution: Connect any add-on electrically operated equipment to the vehicle's electrical system at the battery (power and ground) in order to prevent damage to the vehicle. Aftermarket, add-on, electrical and vacuum equipment is defined as any equipment installed on a vehicle after leaving the factory that connects to the vehicles electrical or vacuum systems. No allowances have been made in the vehicle design for this type of equipment. Add-on electrical equipment, even when installed to these strict guidelines, may still cause the powertrain system to malfunction. This may also include equipment not connected to the vehicle electrical system, such as portable telephones and radios. Therefore, the first step in diagnosing any powertrain condition is to make sure all of the after-market electrical equipment is removed or disconnected from the vehicle. After this has been done and if the condition still exists, the condition may be diagnosed in the normal manner. Electrostatic Discharge (ESD) Damage Note: In order to prevent possible electrostatic discharge damage to the ECM, do not touch the connector pins on the ECM. The electronic components that are used in the control systems are often designed to carry very low voltage. The electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 V of static electricity can cause damage to some electronic components. By comparison, it takes as much as 4 000 V for a person to even feel the zap of a static discharge. There are several ways for a person to become statically charged. The most common methods of charging are by friction and by induction. An example of charging by friction is a person sliding across a car seat. Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground. Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage, therefore, it is important to exercise great care when handling and testing electronic components. Emission Control Information Label The underhood vehicle emissions control information label contains important emission specifications and setting procedures. This identifies the year, the manufacturing division of the engine, the displacement of the engine in liters, the class of the vehicle, and type of fuel metering system. There is also an illustrated emission components and vacuum hose schematic. This label is located in the engine compartment of every General Motors vehicle. If the label has been removed, it can be ordered from GM service parts operations (GMSPO). Underhood Inspection Note: This inspection is very important and must be done carefully and thoroughly. Perform a careful underhood inspection when performing any diagnostic procedure or diagnosing the cause of an emission test failure. This can often lead to repairing a condition without further steps. Use the following guidelines when performing an inspection: * Inspect all of the vacuum hoses for correct routing, pinches, cuts, or disconnects. * Inspect any hoses that are difficult to see. * Inspect all of the wires in the engine compartment for the following conditions: - Burned or chafed spots - Pinched wires - Contact with sharp edges - Contact with hot exhaust manifolds Basic Knowledge Required Caution: Lack of basic knowledge of this powertrain when performing diagnostic procedures could result in incorrect diagnostic performance or damage to powertrain components. Do not attempt to diagnose a powertrain problem without this basic knowledge. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 262 A basic understanding of hand tools is necessary in order to effectively use this section of the service manual. You must be familiar with some of the basics of engine operation and electrical diagnosis in order to use this section of the service manual. * Basic electrical circuits, You should have an understanding of basic electricity and know the meaning of voltage (V), current (A), and resistance (ohm). You should understand what happens in a circuit with an open or a shorted wire, and you should be able to identify a shorted or open circuit by using a digital multimeter (DMM). You should be able to read and understand a wiring diagram. * Use of digital multimeter, You should be familiar with the DMM, particularly the essential tool. You should be able to use the meter in order to measure the voltage (V), the resistance (ohm), the current (A), intermittent (minimum/maximum), and frequency (Hz). * Use of circuit testing tools, You should not use a test lamp to diagnose the engine controls system unless you are specifically instructed to do so. You should know how to use jumper wires in order to test the components and allow DMM readings without damaging the terminals. You should know how to use the J 35616 - Adapter Kit and use the kit whenever the diagnostic procedures call for front probing any connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 263 Engine Control Module: Service and Repair Engine Control Module Replacement Removal Procedure Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note: It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last engine oil change. 1. Prepare the engine control module for the replacement. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). 2. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 3. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 4. Disconnect the 2 wiring harness plug (2) from the engine control module (3). 5. Unclip the engine control module bracket (4) from the battery tray. 6. Remove the 4 nuts (1). 7. Remove the engine control module (3) from the engine control module bracket (4). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 264 1. Install the engine control module (3) to the engine control module bracket (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 4 nuts (1) and tighten to 9 Nm (80 lb in). 3. Clip the engine control module bracket (4) to the battery tray. 4. Connect the 2 wiring harness plug (2) to the engine control module (3). 5. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 6. Program the ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood Main Relay (Computer/Fuel System): Locations Fuse Block - Underhood Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 269 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 270 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 271 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 272 Main Relay (Computer/Fuel System): Locations Fuse Block - Instrument Panel Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 273 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 278 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 279 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 280 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood Main Relay (Computer/Fuel System): Locations Fuse Block - Underhood Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 285 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 286 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 287 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 288 Main Relay (Computer/Fuel System): Locations Fuse Block - Instrument Panel Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 289 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations Ignition Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 294 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 295 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 296 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 297 Ignition Relay: Testing and Inspection Ignition Relay Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description The powertrain relay, is controlled by the engine control module (ECM) depending upon input from the ignition switch. Battery positive voltage is supplied to the relay coil and switch. When the ignition switch is turned to the ON position, the ECM will provide ground on the control circuit of the relay using a low side driver. This will allow voltage through the relay switch contacts to the components. The ECM monitors the voltage level on the control circuit of the relay. Diagnostic Aids The relay electrical contacts may be pitted or sticking. Replace the powertrain relay , if gently tapping or wiggling the powertrain relay causes a change in the relays operation. Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams/Powertrain Management/System Diagram) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) DTC Type Reference Powertrain Diagnostic Trouble Code (DTC) Type Definitions (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Powertrain Diagnostic Trouble Code (DTC) Type Definitions) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Special Tools EL 43244 - Relay Puller Pliers For equivalent regional tools, refer to Special Tools (See: Powertrain Management/Computers and Control Systems/Tools and Equipment). Circuit/System Verification Warning An electric fan under the hood can start up even when the engine is not running and can injure you. Keep hands, clothing and tools away from any underhood electric fan. 1. Cycle the ignition from OFF to ON. You should hear and feel an audible click from the KR75 Powertrain Relay. Repeat as necessary in order to verify KR75 Powertrain Relay operation. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 298 2. Operate the vehicle within the Conditions for running the DTC to verify the DTC does not reset. You may also operate the vehicle within the conditions that you observed from the freeze frame/failure records data. Circuit/System Testing 1. Ignition OFF, disconnect the KR75 Powertrain Relay. 2. Ignition ON, verify a test lamp illuminates between the KR75 Powertrain Relay coil ignition voltage circuit terminal 85 and ground. ‹› If the test lamp does not illuminate, repair the KR75 Powertrain Relay coil ignition voltage circuit for a short to ground or an open/high resistance. Replace the fuse if necessary. 3. Ignition OFF, connect a test lamp between the KR75 Powertrain Relay coil control circuit terminal 86 and the KR75 Powertrain Relay coil ignition voltage circuit terminal 85. ‹› If the test lamp is always ON, test the KR75 Powertrain Relay control circuit for a short to ground. If the circuit tests normal, replace the K20 Engine Control Module. 4. Ignition ON. The test lamp should turn ON. ‹› If the test lamp is always OFF, test the KR75 Powertrain Relay ECM control circuit for a short to voltage or an open/high resistance. If circuit tests normal, replace the K20 Engine Control Module. Note: The ignition voltage circuit is between the KR75 Powertrain Relay and the ECM. The ignition voltage is a feedback circuit. 5. Install a 20 A fused jumper wire between the KR75 Powertrain Relay switch B+ circuit terminal 30 and the KR75 Powertrain Relay switch ignition voltage circuit terminal 87. 6. Attempt to start the engine. The engine should start. ‹› If the engine does not start, test the ignition voltage circuit between the KR75 Powertrain Relay and the K20 Engine Control Module for a short to ground or for an open/high resistance. If the circuit tests normal, replace the K20 Engine Control Module. 7. If all circuits test normal, test or replace the KR75 Powertrain Relay. Component Testing Relay Test 1. Ignition OFF, remove the KR75 Powertrain Relay from the electrical center with the EL 43244 Relay Puller Pliers. 2. Test for 70-110 ohm between terminals 85 and 86. ‹› If not within the specified range, replace the KR75 Powertrain Relay. 3. Test for infinite resistance between the following terminals: * 30 and 86 * 30 and 87 * 30 and 85 * 85 and 87 ‹› If not the specified value, replace the KR75 Powertrain Relay. 4. Install a 20 A fused jumper wire between KR75 Powertrain Relay terminal 85 and 12 V. Install a jumper wire between KR75 Powertrain Relay terminal 86 and ground. Test for less than 2 ohm between terminals 30 and 87. ‹› If greater than the specified range, replace the KR75 Powertrain Relay. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Relay Replacement (Attached to Wire Harness) (See: Relays and Modules - Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Relays and Modules - Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) * Control Module References (See: Testing and Inspection/Programming and Relearning)for ECM replacement, setup, and programming Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Instrument Panel/Center Console Component Views Behind the Center of the I/P Components 3 of 4 1 - K36 Inflatable Restraint Sensing and Diagnostic Module 2 - X2 Inflatable Restraint Sensing and Diagnostic Module X2 3 - X1 Inflatable Restraint Sensing and Diagnostic Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 303 Air Bag Control Module: Diagrams Component Connector End Views K36 Inflatable Restraint Sensing and Diagnostic Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 304 Air Bag Control Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 309 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 310 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 311 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Wheels/Vehicle Underbody Component Views Front Frame and Underbody Components (NJ1) 1 - X1 Power Steering Control Module X1 2 - X2 Power Steering Control Module X2 3 - K43 Power Steering Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 317 Steering Control Module: Service and Repair Power Steering Control Module Calibration Steering Angle Sensor Centering and Software Endstop Learning Warning An inaccurate or not centered steering angle sensor could limit the operation of the electric power steering (EPS) and result in personal injury. Centering of the steering angle sensor and software endstop learning might be required after certain service procedures are performed. Some of these procedures are as follows: * Steering angle sensor replacement * Steering gear replacement * Power steering assist motor replacement * Steering column replacement * Steering linkage inner tie rod replacement * Steering linkage outer tie rod replacement Note: It is necessary to perform the steering angle sensor centering before the software endstop learning. Steering Angle Sensor Centering For the centering procedure of the external steering angle sensor (electronic stability program) refer to Steering Angle Sensor Centering (See: Sensors and Switches/Sensors and Switches Steering and Suspension/Sensors and Switches - Steering/Steering Angle Sensor/Service and Repair/Procedures). The centering procedure of the internal steering angle sensor (w/o electronic stability program) can be completed with the following steps: Conditions: Front axle measured and set, engine running, vehicle speed 0 km/h (0 MPH), internal steering angle sensor is activated. 1. Using the steering wheel, align the front wheels in the center forward position. 2. Using a scan tool, perform the Configuration/Reset Functions, Steering Wheel Angle Sensor Centering procedure. 3. Steer from the center position slowly 90° to the left. 4. Steer slowly back to the center position and then slowly 90° to the right. 5. Steer slowly back to the center position. 6. Perform the steering movements again. 7. Centering procedure is completed. Software Endstop Learning The software endstop learning procedure can be completed with the following steps: Conditions: Front axle measured and set, vehicle speed 0 km/h (0 MPH), internal steering angle sensor is calibrated or external steering angle sensor sends a valid CAN signal. 1. Using a scan tool, perform the Configuration/Reset Functions, Power Steering Softstops Reset procedure and follow the on-screen instructions. 2. Using a scan tool, perform the Configuration/Reset Functions, Power Steering Softstops Learn procedure and follow the on-screen instructions. 3. Software endstop learning procedure is completed. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Recalls for Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues Control Module: Recalls Campaign - Thermostat Sticks Open Causes Shift Issues SERVICE UPDATE Bulletin No.: 10399A Date: December 02, 2010 Subject: 10399A - Service Update for Inventory and Customer Vehicles - Powertrain Improvements - Thermostat Sticks in Open Position and Shift Quality - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with a 1.4L Turbo Engine (LUJ) Supercede: The Subject and Purpose in this bulletin are being revised to advise that the new ECM calibration will also address shift quality issues.Please discard all copies of bulletin 10399, issued November 2010. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to reprogram the engine control module (ECM) on certain 2011 model year Chevrolet Cruze vehicles equipped with a 1.4L turbo engine (LUJ). These vehicles may have a condition where the thermostat sticks in the open position. If this occurs, diagnostic codes will be set and the Service Vehicle Soon light/message will illuminate. These vehicles may also have transmission shift quality issues due to calibration values. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. Additionally, a list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should also be checked for vehicle eligibility. Parts Information No parts are required for this update. Service Procedure Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 11/29/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming. 2. Reprogram the engine control module (ECM) and transmission control module (TCM) in sequence. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI or Tech 2(R) to the vehicle. If using MDI, connect to programming terminal with the cable (USB or LAN). 2. Select J-2534 MDI or J-2534 Tech 2(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Recalls for Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues > Page 333 3. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. 4. Follow the on-screen instructions. 3. Clear all DTCs using the GDS or Tech 2(R). Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues Control Module: All Technical Service Bulletins Campaign - Thermostat Sticks Open Causes Shift Issues SERVICE UPDATE Bulletin No.: 10399A Date: December 02, 2010 Subject: 10399A - Service Update for Inventory and Customer Vehicles - Powertrain Improvements - Thermostat Sticks in Open Position and Shift Quality - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with a 1.4L Turbo Engine (LUJ) Supercede: The Subject and Purpose in this bulletin are being revised to advise that the new ECM calibration will also address shift quality issues.Please discard all copies of bulletin 10399, issued November 2010. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to reprogram the engine control module (ECM) on certain 2011 model year Chevrolet Cruze vehicles equipped with a 1.4L turbo engine (LUJ). These vehicles may have a condition where the thermostat sticks in the open position. If this occurs, diagnostic codes will be set and the Service Vehicle Soon light/message will illuminate. These vehicles may also have transmission shift quality issues due to calibration values. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. Additionally, a list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should also be checked for vehicle eligibility. Parts Information No parts are required for this update. Service Procedure Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 11/29/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming. 2. Reprogram the engine control module (ECM) and transmission control module (TCM) in sequence. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI or Tech 2(R) to the vehicle. If using MDI, connect to programming terminal with the cable (USB or LAN). 2. Select J-2534 MDI or J-2534 Tech 2(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues > Page 339 3. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. 4. Follow the on-screen instructions. 3. Clear all DTCs using the GDS or Tech 2(R). Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 340 Control Module: Locations Powertrain Component Views Transmission Components (MH8) 1 - T12 Automatic Transmission Assembly 2 - X1 Transmission Control Module X1 3 - T12 Automatic Transmission Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 345 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 346 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 347 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations Windshield Washer Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 352 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 353 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 354 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 358 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 359 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 360 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations Parking Assist Distance Sensor: Locations Luggage Compartment/Rear of Vehicle Component Views Rear of the Vehicle Components 1 - B78G Rear Object Sensor - Left Outer 2 - B78E Rear Object Sensor - Left Middle 3 - B78F Rear Object Sensor - Right Middle 4 - B78H Rear Object Sensor - Right Outer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Page 366 Parking Assist Distance Sensor: Diagrams Component Connector End Views B78E Rear Object Sensor - Left Middle (UD7) B78F Rear Object Sensor - Right Middle (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Page 367 B78G Rear Object Sensor - Left Outer (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Page 368 B78H Rear Object Sensor - Right Outer (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Page 369 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Housing Replacement Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement Rear Object Sensor Housing Replacement 1. Remove the rear fascia. Refer to Rear Bumper Fascia Replacement (See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Replacement). 2. Disconnect the sensor harness. 3. Remove the sensor from the sensor housing. The sensor housing must be painted if replaced. If reinstalled, painting will not be necessary. Important: Do Not grind off alignment tabs. 4. Sand/grind sonic weld plastic residue from the fascia. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Housing Replacement > Page 372 5. Apply structural adhesive epoxy, Lord Fusor(TM) 127EZ or equivalent, to fascia at mating surface. 6. Using the alignment tabs, install the sensor housing to the fascia. 7. Allow adhesive to cure according to manufacturer's directions. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Housing Replacement > Page 373 8. Install the sensor to the sensor housing. 9. Connect the electrical harness. 10. Install the rear fascia. Refer to Rear Bumper Fascia Replacement (See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Housing Replacement > Page 374 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Replacement Rear Object Sensor Replacement Removal Procedure 1. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement (See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Replacement) 2. Disconnect electrical from the rear object sensor. 3. Lift the locking tabs on the housing and remove the rear object sensor. Installation Procedure 1. Insert the sensor into the housing. 2. Connect the electrical connector to the rear object sensor. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Housing Replacement > Page 375 3. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement (See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Locations Pedal Positioning Sensor: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Locations > Page 379 Pedal Positioning Sensor: Diagrams Component Connector End Views B22 Brake Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Service and Repair > Brake Pedal Position Sensor Calibration Pedal Positioning Sensor: Service and Repair Brake Pedal Position Sensor Calibration Brake Pedal Position Sensor Calibration Calibration Criteria Note: Do not apply the brake pedal during the brake pedal position sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the brake pedal position sensor calibration must be repeated. Brake pedal position sensor calibration must be performed after the brake pedal position sensor or body control module (BCM) have been serviced. The calibration procedure will set the brake pedal position sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. Calibration Procedure 1. Apply the parking brake. 2. Place the transmission in the PARK position. 3. Install a scan tool. 4. Navigate to the Module Diagnosis menu. 5. Clear all BCM DTCs before proceeding. 6. Navigate to the Configuration/Reset Functions menu of the BCM. 7. Select Brake Pedal Position Sensor Learn. 8. Select the Brake Pedal Position Sensor Learn procedure and follow the directions displayed on the screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Service and Repair > Brake Pedal Position Sensor Calibration > Page 382 Pedal Positioning Sensor: Service and Repair Brake Pedal Position Sensor Replacement Brake Pedal Position Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Ajar Switch > Component Information > Diagrams Hood Ajar Switch: Diagrams Component Connector End Views B55 Hood Ajar Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Locations Pedal Positioning Sensor: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Locations > Page 391 Pedal Positioning Sensor: Diagrams Component Connector End Views B22 Brake Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Service and Repair > Brake Pedal Position Sensor Calibration Pedal Positioning Sensor: Service and Repair Brake Pedal Position Sensor Calibration Brake Pedal Position Sensor Calibration Calibration Criteria Note: Do not apply the brake pedal during the brake pedal position sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the brake pedal position sensor calibration must be repeated. Brake pedal position sensor calibration must be performed after the brake pedal position sensor or body control module (BCM) have been serviced. The calibration procedure will set the brake pedal position sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. Calibration Procedure 1. Apply the parking brake. 2. Place the transmission in the PARK position. 3. Install a scan tool. 4. Navigate to the Module Diagnosis menu. 5. Clear all BCM DTCs before proceeding. 6. Navigate to the Configuration/Reset Functions menu of the BCM. 7. Select Brake Pedal Position Sensor Learn. 8. Select the Brake Pedal Position Sensor Learn procedure and follow the directions displayed on the screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Service and Repair > Brake Pedal Position Sensor Calibration > Page 394 Pedal Positioning Sensor: Service and Repair Brake Pedal Position Sensor Replacement Brake Pedal Position Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations Instrument Panel/Center Console Component Views Center of the I/P Components 1 - P16 Instrument Cluster 2 - P17 Info Display Module 3 - S26 Hazard Lamps Switch 4 - A26 HVAC Control 5 - S13D Door Lock Switch - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 398 Power Door Lock Switch: Diagrams Component Connector End Views S13D Door Lock Switch - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 399 Power Door Lock Switch: Service and Repair Door Lock Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Door Component Views Driver Door Components 1 - S79D Window Switch - Driver 2 - S52 Outside Rearview Mirror Switch 3 - A9A Outside Rearview Mirror - Driver 4 - P19G Speaker - Left Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 403 Power Mirror Switch: Diagrams Component Connector End Views S52 Outside Rearview Mirror Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 404 Power Mirror Switch: Service and Repair Outside Remote Control Rearview Mirror Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Replacement Power Seat Switch: Service and Repair Driver or Passenger Seat Adjuster Switch Replacement Driver or Passenger Seat Adjuster Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Replacement > Page 409 Power Seat Switch: Service and Repair Driver Seat Adjuster Switch Replacement Driver Seat Adjuster Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Sunroof / Moonroof Switch: Locations Passenger Compartment/Roof Component Views Overhead Console Components 1 - S72 Sunroof Switch 2 - S88 Sunroof Ventilation Switch 3 - E37B Dome / Reading Lamps - 2nd Row 4 - K61 Sunroof Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 413 Sunroof / Moonroof Switch: Diagrams Component Connector End Views S72 Sunroof Switch (CF5) S88 Sunroof Tilt Switch (CF5) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 414 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 415 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations Trunk / Liftgate Switch: Locations Luggage Compartment/Rear of Vehicle Component Views Trunk Components 2 of 2 1 - E7 License Plate Lamp 2 - S58A Rear Compartment Lid Unlatch Switch - Exterior 3 - E7 License Plate Lamp Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Acceleration/Deceleration Sensor > Component Information > Locations Acceleration/Deceleration Sensor: Locations Instrument Panel/Center Console Component Views Center Console Components 2 of 5 1 - G307 Tunnel 2 - B119 Multi-axis Acceleration Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Acceleration/Deceleration Sensor > Component Information > Locations > Page 423 Acceleration/Deceleration Sensor: Diagrams Component Connector End Views B119 Multi-Axis Acceleration Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Diagrams Brake Booster Vacuum Sensor: Diagrams Component Connector End Views B19C Brake Booster Vacuum Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Brake Fluid Level Sensor/Switch: Diagrams Component Connector End Views B20 Brake Fluid Level Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 430 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Indicator Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations Parking Brake Release Switch: Locations Instrument Panel/Center Console Component Views Center Console Components 1 of 5 1 - B80 Park Brake Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Page 434 Parking Brake Release Switch: Diagrams Component Connector End Views B80 Park Brake Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Passenger Compartment/Roof Component Views Wheel Speed Sensor: Locations Passenger Compartment/Roof Component Views Passenger Compartment/Roof Component Views Left Rear of the Passenger Compartment Components 1 of 2 1 - F105L Roof Rail Air Bag - Left 2 - B63LR Side Impact Sensor - Left Rear 3 - B5LR Wheel Speed Sensor - Left Rear 4 - G309 Panel Rear - Left 5 - G401 Panel Rear - Left Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Passenger Compartment/Roof Component Views > Page 442 Wheel Speed Sensor: Locations Wheels/Vehicle Underbody Component Views Wheels/Vehicle Underbody Component Views Right Rear Frame and Underbody Components 1 - B5RR Wheel Speed Sensor - Right Rear Left Front Frame and Underbody Components 1 of 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Passenger Compartment/Roof Component Views > Page 443 1 - B5LF Wheel Speed Sensor - Left Front Right Front Frame and Underbody Components Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Passenger Compartment/Roof Component Views > Page 444 1 - B5RF Wheel Speed Sensor - Right Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 445 Wheel Speed Sensor: Diagrams Component Connector End Views B5LF Wheel Speed Sensor - Left Front B5LR Wheel Speed Sensor - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 446 B5RF Wheel Speed Sensor - Right Front B5RR Wheel Speed Sensor - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 447 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement Front Wheel Speed Sensor Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the wheel speed sensor screw (2) from the steering knuckle. 4. Remove the wheel speed sensor (1). 5. Remove the wiring harness retainers from the frame. 6. Disconnect the electrical connector. 7. Remove wheel speed sensor (1) from the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 450 Installation Procedure 1. Install the wheel speed sensor (1) to the vehicle. 2. Connect the electrical connector. 3. Install the wiring harness retainers to the frame. 4. Install the wheel speed sensor (1) to the steering knuckle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the wheel speed sensor screw (2) and tighten to 9 Nm (80 lb in). 6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 451 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement (Disc Brake) Rear Wheel Speed Sensor Replacement (Disc Brake) Removal Procedure 1. Remove rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). 2. Remove the wheel speed sensor screw (2) from the steering knuckle. 3. Remove the wheel speed sensor (1). 4. Remove the wiring harness (3) from the bracket (4). 5. Remove the wiring harness (2) retainers (3) from the brake hose (4). 6. Remove the wiring harness (2) from the body retainer (1). 7. Replace the body retainer (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 452 8. Disconnect the electrical connector (1). 9. Remove wheel speed sensor from the vehicle. Installation Procedure 1. Install the wheel speed sensor to the vehicle. 2. Connect the electrical connector (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 453 3. Install the wiring harness (2) retainers (3) to the TOP SIDE of brake hose (4), using the marking points of old wiring harness. 4. Install the wiring harness (2) to the NEW body retainer (1). 5. Install the wheel speed sensor (1) to the steering knuckle. 6. Install the wiring harness (3) at the bracket (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the wheel speed sensor screw (2) and tighten to 6 Nm (53 lb in). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 454 8. Check the correct installation position of the wiring harness (1). The wiring harness MUST be routed on top of the brake hose. If necessary adjust retainers (2) to the marking positions on the brake hose. 9. Apply tension to the wiring harness (1) between the retainers (2) for the correct routing. 10. Push down the brake hose by hand, to assure the correct installation position. 11. Install the rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 455 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement (Drum Brake) Rear Wheel Speed Sensor Replacement (Drum Brake) Removal Procedure 1. Remove rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). 2. Remove the wheel speed sensor screw (2) from the steering knuckle. 3. Remove wheel speed sensor (1). 4. Remove wiring harness (3) from bracket (4). 5. Disconnect the electrical connector (1). 6. Remove wheel speed sensor from vehicle. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 456 1. Install the wheel speed sensor to the vehicle. 2. Connect the electrical connector (1). 3. Install the wheel speed sensor (1) to steering knuckle. 4. Install wiring harness (3) at the bracket (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the wheel speed sensor screw (2) and tighten to 9 Nm (80 lb in). 6. Install rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Testing and Inspection Yaw Rate Sensor: Testing and Inspection Vehicle Yaw Sensor Learn The yaw sensor does not require calibration often. Calibration of the yaw rate sensor might be required after certain service procedures are performed. Some of these procedures are as follows: * Electronic brake control module (EBCM) replacement * Multi-axis acceleration sensor replacement The yaw rate sensor calibration procedure can be completed with a scan tool using the following steps: 1. Place vehicle on a level surface 2. Apply the parking brake, or set the transmission in the P position. 3. Install the scan tool to the data link connector. 4. Ignition ON, engine OFF. 5. Select Yaw Rate Sensor Reset in the Multi-axis Acceleration Sensor Module Configuration/Reset Functions list. 6. Follow the scan tool directions to complete the calibration procedure. 7. Select Yaw Rate Sensor Learn in the Multi-axis Acceleration Sensor Module Configuration/Reset Functions list. 8. Follow the scan tool directions to complete the calibration procedure. 9. Select Yaw Rate Sensor Learn in the EBCM Configuration/Reset Functions list. 10. Follow the scan tool directions to complete the calibration procedure. 11. Clear any DTCs that may be set. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Testing and Inspection > Page 460 Yaw Rate Sensor: Service and Repair Vehicle Yaw Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Service and Repair Coolant Level Sensor: Service and Repair Engine Coolant Level Indicator Module Replacement (LDD, LUH, LUJ, LDE, LLU, LUW) (1.4L, 1.8L) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Powertrain Component Views Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Powertrain Component Views Engine Components - Left Rear (LUJ) 1 - B111 Turbocharger Boost Pressure Sensor 2 - T8 Ignition Coil 3 - B68 Knock Sensor (KS) 4 Q38 Throttle Body 5 - B34 Engine Coolant Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Powertrain Component Views > Page 470 Coolant Temperature Sensor/Switch (For Computer): Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components 1 - G105 Engine Compartment - Front Left 2 - G10 Cooling Fan Motor 3 - B34B Engine Coolant Temperature Sensor 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Engine Coolant Temperature Sensor Replacement (Radiator) Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement (Radiator) Engine Coolant Temperature Sensor Replacement (Radiator) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Engine Coolant Temperature Sensor Replacement (Radiator) > Page 473 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement (Water Outlet) Engine Coolant Temperature Sensor Replacement (Water Outlet) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair Cruise Control Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Powertrain Component Views Engine Components - Right Front (LUJ) 1 - Q6E Camshaft Position Actuator Solenoid Valve - Exhaust 2 - B23E Camshaft Position Sensor Exhaust 3 - B37 Engine Oil Pressure Switch 4 - B52A Heated Oxygen Sensor 1 5 - Q42 Turbocharger Wastegate Solenoid Valve 6 - Q2 A/C Compressor Clutch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations Oil Pressure Switch (For Fuel Pump): Locations Disassembled Views Cylinder Head Assembly 1 - Camshaft Cover 2 - Oil Level Indicator 3 - Camshaft Cover Bolt 4 - Oil Filler Cap 5 - Oil Filler Cap Seal Ring 6 - Camshaft Cover Gasket 7 - Camshaft Bearing Cap Bolt 8 - Camshaft Bearing Cap 9 - Cylinder Head Bolt 10 - Valve Keys 11 - Valve Spring Retainer 12 - Valve Spring 13 Engine Lift Bracket Left Side 14 - Engine Lift Bracket Bolt 15 - Cylinder Head 16 - Intake Valve Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 485 17 - Exhaust Valve 18 - Engine Lift Bracket 19 - Engine Lift Bracket Bolt 20 - Engine Lift Bracket 21 - Engine Lift Bracket Bolt 22 - Oil Pressure Indicator Switch 23 - Oil Pressure Indicator Switch Seal Ring 24 - Hydraulic Valve Lash Adjuster 25 - Hydraulic Valve Lash Adjuster Arm 26 - Exhaust Camshaft 27 - Intake Camshaft Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 486 Oil Pressure Switch (For Fuel Pump): Service and Repair Engine Oil Pressure Indicator Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Locations Air Conditioning Switch: Locations Component Connector End Views S34 HVAC Controls Switch Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications Ambient Temperature Sensor / Switch HVAC: Specifications Ambient Air Temperature Sensor Resistance Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views Ambient Temperature Sensor / Switch HVAC: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components 2 of 2 1 - B108 Air Quality Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 496 Ambient Temperature Sensor / Switch HVAC: Locations Wheels/Vehicle Underbody Component Views Wheels/Vehicle Underbody Component Views Left Front Frame and Underbody Components 2 of 2 1 - B9 Air Temperature Sensor - Ambient Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 497 Ambient Temperature Sensor / Switch HVAC: Diagrams Component Connector End Views B9 Air Temperature Sensor - Ambient Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 498 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Quality Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations Cabin Temperature Sensor / Switch: Locations Instrument Panel/Center Console Component Views Behind the Left Side of the I/P Components (C68) 1 - 7D Air Temperature Sensor - Duct Left Lower 2 - M6L Air Temperature Door Actuator - Left 3 M37 Mode Door Actuator 4 - B7H Air Temperature Sensor - Duct Left Upper Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Inside Air Temperature Sensor Replacement (Left Hand Drive) Cabin Temperature Sensor / Switch: Service and Repair Inside Air Temperature Sensor Replacement (Left Hand Drive) Inside Air Temperature Sensor Replacement (Left Hand Drive) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Inside Air Temperature Sensor Replacement (Left Hand Drive) > Page 504 Cabin Temperature Sensor / Switch: Service and Repair Inside Air Moisture and Windshield Temperature Sensor Replacement Inside Air Moisture and Windshield Temperature Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Climate Control Exhaust Gas Sensor > Component Information > Diagrams Climate Control Exhaust Gas Sensor: Diagrams Component Connector End Views B108 Air Quality Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Powertrain Component Views Lower Right Side of the Engine Components 1 - B1 A/C Refrigerant Pressure Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 511 Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Temperature Sensor > Component Information > Service and Repair > HVAC - Automatic Refrigerant Temperature Sensor: Service and Repair HVAC - Automatic Air Conditioning Refrigerant Temperature Sensor Replacement - Right Side (Left Hand Drive) Air Conditioning Refrigerant Temperature Sensor Replacement - Right Side (Left Hand Drive) Air Conditioning Refrigerant Temperature Sensor Replacement - Left Side (Left Hand Drive) Air Conditioning Refrigerant Temperature Sensor Replacement - Left Side (Left Hand Drive) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Temperature Sensor > Component Information > Service and Repair > HVAC - Automatic > Page 516 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Temperature Sensor > Component Information > Service and Repair > HVAC - Automatic > Page 517 Refrigerant Temperature Sensor: Service and Repair HVAC - Manual Air Conditioning Refrigerant Temperature Sensor Replacement - Right Side (Left Hand Drive) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Service and Repair Solar Sensor: Service and Repair Sun Load Temperature and Headlamp Automatic Control Ambient Light Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ventilation Switch > Component Information > Service and Repair Ventilation Switch: Service and Repair Vent Valve Lever Replacement (Left Hand Drive) Removal Procedure 1. Remove instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Note: The graphic shows air inlet housing without attaching parts for better clarity. 2. Disconnect electrical connector and remove 3 mode control cam actuator screws (2) and remove mode control cam actuator (1). 3. Remove air inlet valve and inside air valve control cam (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ventilation Switch > Component Information > Service and Repair > Page 524 4. Remove 2 vent valve levers (1). Installation Procedure 1. Install 2 vent valve levers (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ventilation Switch > Component Information > Service and Repair > Page 525 Note: The vent valve levers have to be fitted to the according vent valve gears in figured position. The air circulation dampers have to be in middle position. 2. Make sure that mode valve gears of valve vent levers (1) are fitted as shown in graphic above Note: The air inlet valve and inside air valve control cam can only be fitted in one position. 3. Install air inlet valve and inside air valve control cam (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ventilation Switch > Component Information > Service and Repair > Page 526 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install mode control cam actuator (1) and install 3 mode control cam actuator screws (2) and connect electrical connector. 2.5 Nm (23 lb in). 5. Install instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair Fuel Gauge Sender: Service and Repair Fuel Sender Assembly Replacement Removal Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning: Refer to Safety Goggles and Fuel Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions/Safety Goggles and Fuel Warning). Caution: Use care while handling the fuel sender to prevent damage and incorrect fuel level readings. 1. Remove the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Tank Fuel Pump Module Replacement). 2. Disconnect the fuel sender assembly wiring harness plugs (1). 3. Unclip the 2 fuel sender retainer pins. 4. Remove the fuel sender assembly (2). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Page 531 1. Install the fuel sender assembly (2). 2. Connect the fuel sender assembly wiring harness plugs (1). 3. Install the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Tank Fuel Pump Module Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Hood Ajar Switch > Component Information > Diagrams Hood Ajar Switch: Diagrams Component Connector End Views B55 Hood Ajar Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Service and Repair Outside Temperature Display Sensor: Service and Repair Ambient Air Temperature Gauge Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ambient Light Sensor: Locations Instrument Panel/Center Console Component Views Behind the Center of the I/P Components 2 of 4 1 - B10B Ambient Light/Sunload Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 545 Ambient Light Sensor: Diagrams Component Connector End Views B10B Ambient Light/Sunload Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Manual Transmission Component Views Backup Lamp Switch: Locations Manual Transmission Component Views Manual Transmission Component Views Clutch Housing Components - Left Hand View 1 - Front Differential Carrier Flange Seal 2 - Front Differential Carrier Flange 3 - Front Wheel Drive Shaft Oil Seal 4 - Front Differential Carrier Flange Bolts (Qty: 4) 5 - Front Differential Carrier Flange Bolt Washers (Qty: 4) 6 - Transmission Oil Drain Plug 7 - Backup Lamp Switch Washer 8 - Backup Lamp Switch 9 - Clutch Actuator Cylinder Pipe Elbow 10 - Clutch Actuator Cylinder Pipe Sleeve Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Manual Transmission Component Views > Page 550 Backup Lamp Switch: Locations Powertrain Component Views Powertrain Component Views Transmission Components (MF3 or MZ0) 1 - B16 Backup Lamp Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 551 Backup Lamp Switch: Service and Repair M32 - Manual Transmission Backup Lamp Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Combination Switch: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 555 Combination Switch: Diagrams Component Connector End Views S78 Turn Signal/Multi-Function Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations Instrument Panel/Center Console Component Views Center of the I/P Components 1 - P16 Instrument Cluster 2 - P17 Info Display Module 3 - S26 Hazard Lamps Switch 4 - A26 HVAC Control 5 - S13D Door Lock Switch - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 559 Hazard Warning Switch: Diagrams Component Connector End Views S26 Hazard Lamps Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 560 Hazard Warning Switch: Service and Repair Hazard Warning Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Sensor > Component Information > Service and Repair Headlamp Dimmer Sensor: Service and Repair Headlamp Automatic Control Ambient Light Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 567 Headlamp Switch: Diagrams Component Connector End Views S30 Headlamp Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 568 Headlamp Switch: Service and Repair Headlamp Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair Steering Wheel Horn Contact Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 575 Turn Signal Switch: Diagrams Component Connector End Views S78 Turn Signal/Multi-Function Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 581 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views B107 Accelerator Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 582 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Right Front of the Vehicle Components 1 of 2 1 - B75B Mass Air Flow/Intake Air Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 586 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor Replacement (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations Barometric Pressure Sensor: Locations Powertrain Component Views Engine Components - Right Rear (LUJ) 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Locations Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Side of the Engine Compartment Components 2 of 2 1 - B18 Battery Current Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Locations > Page 593 Battery Current Sensor: Diagrams Component Connector End Views B18 Battery Current Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Locations > Page 594 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Open the hood. 2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Remove the battery ground cable nut (1). 4. Remove the battery negative cable (2). 5. Disconnect the wiring harness current sensor plug (4). 6. Remove the current sensor (5) from the battery tray. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Locations > Page 595 7. Remove the current sensor (2) from the battery negative cable (1). Installation Procedure 1. Install the current sensor (2) to the battery negative cable (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Locations > Page 596 2. Install the current sensor (5) to the battery tray. 3. Connect the wiring harness current sensor plug (4). 4. Install the battery negative cable (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the battery ground cable nut (1) and tighten to 9 Nm (80 lb in). 6. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 7. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle Camshaft Position Sensor: Customer Interest Engine - Lack of Power with Multiple DTCs or Rattle TECHNICAL Bulletin No.: 10-06-04-016 Date: December 20, 2010 Subject: Engine Lack of Power with DTCs P0011, P0014, P000A, P000B, P0012, P0015 or Engine Rattle Noise (Remove Oil Filters from Intake and Exhaust Camshaft Position Actuator Solenoid Valves) Models: 2008-2011 Chevrolet Aveo 2011 Chevrolet Cruze (US and Canada) 2009-2011 Chevrolet Cruze (Export Only) 2008-2009 Pontiac G3, Wave 2008-2009 Saturn Astra Condition Some customers may comment on lack of power with the following DTCs or an engine rattle noise from the sprockets. Cruze GEN3 1.6/1.8D - P0011: Intake Camshaft Position (CMP) System Performance - P0014: Exhaust Camshaft Position (CMP) System Performance - P000A: Intake Camshaft Position System Slow Response - P000B: Exhaust Camshaft Position System Slow Response Aveo GEN3 1.4D - P0012: Intake Camshaft Position (CMP) System Performance Bank 1-Retarded - P0015: Exhaust Camshaft Position (CMP) System Performance Bank 1-Retarded Aveo/G3/Wave Gen3 1.6D - P0011: Intake Camshaft Position (CMP) System Performance Bank 1 - P0014: Exhaust Camshaft Position (CMP) System Performance Bank 1 Correction Remove four oil filters from the intake and exhaust camshaft position actuator solenoid valves. 1. Open the hood. 2. Disconnect the negative battery cable. 3. Disconnect the camshaft position actuator solenoid valve connectors. 4. Remove the power steering line bracket bolt and reposition the bracket (for 1.6/1.8L only). 5. Disconnect PCV pipe and reposition (for 1.6/1.8L only). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 605 6. Remove the camshaft position actuator solenoid valve bolts. 7. Remove the camshaft position actuator solenoid valves and seals. 8. Check whether the filter is broken or not (1). 9. Remove the four filters (intake and exhaust). 1. Broken Filter: Remove filter with a blunt tool. 2. Unbroken Filter 1. Locate the filter hinge between the holes. 2. Cut the filter hinge slightly. Caution Do not scratch the valve surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 606 3. Remove the filter with a blunt tool. 10. Install the camshaft position actuator solenoid valves and seals. Coat the seal with clean engine oil prior to installation. 11. Install the camshaft position actuator solenoid valve bolts. Tighten Tighten the bolts to 6 Nm (53 lb in). 12. Connect the camshaft position actuator solenoid valve connectors. 13. Reposition and install the PCV pipe (for 1.6/1.8 only). 14. Reposition the power steering bracket and install the power steering line bracket bolt (for 1.6/1.8 only). 15. Connect the negative battery cable. Note If an engine rattle noise is heard after removing the filters, refer to SI for further diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle Camshaft Position Sensor: All Technical Service Bulletins Engine - Lack of Power with Multiple DTCs or Rattle TECHNICAL Bulletin No.: 10-06-04-016 Date: December 20, 2010 Subject: Engine Lack of Power with DTCs P0011, P0014, P000A, P000B, P0012, P0015 or Engine Rattle Noise (Remove Oil Filters from Intake and Exhaust Camshaft Position Actuator Solenoid Valves) Models: 2008-2011 Chevrolet Aveo 2011 Chevrolet Cruze (US and Canada) 2009-2011 Chevrolet Cruze (Export Only) 2008-2009 Pontiac G3, Wave 2008-2009 Saturn Astra Condition Some customers may comment on lack of power with the following DTCs or an engine rattle noise from the sprockets. Cruze GEN3 1.6/1.8D - P0011: Intake Camshaft Position (CMP) System Performance - P0014: Exhaust Camshaft Position (CMP) System Performance - P000A: Intake Camshaft Position System Slow Response - P000B: Exhaust Camshaft Position System Slow Response Aveo GEN3 1.4D - P0012: Intake Camshaft Position (CMP) System Performance Bank 1-Retarded - P0015: Exhaust Camshaft Position (CMP) System Performance Bank 1-Retarded Aveo/G3/Wave Gen3 1.6D - P0011: Intake Camshaft Position (CMP) System Performance Bank 1 - P0014: Exhaust Camshaft Position (CMP) System Performance Bank 1 Correction Remove four oil filters from the intake and exhaust camshaft position actuator solenoid valves. 1. Open the hood. 2. Disconnect the negative battery cable. 3. Disconnect the camshaft position actuator solenoid valve connectors. 4. Remove the power steering line bracket bolt and reposition the bracket (for 1.6/1.8L only). 5. Disconnect PCV pipe and reposition (for 1.6/1.8L only). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 612 6. Remove the camshaft position actuator solenoid valve bolts. 7. Remove the camshaft position actuator solenoid valves and seals. 8. Check whether the filter is broken or not (1). 9. Remove the four filters (intake and exhaust). 1. Broken Filter: Remove filter with a blunt tool. 2. Unbroken Filter 1. Locate the filter hinge between the holes. 2. Cut the filter hinge slightly. Caution Do not scratch the valve surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 613 3. Remove the filter with a blunt tool. 10. Install the camshaft position actuator solenoid valves and seals. Coat the seal with clean engine oil prior to installation. 11. Install the camshaft position actuator solenoid valve bolts. Tighten Tighten the bolts to 6 Nm (53 lb in). 12. Connect the camshaft position actuator solenoid valve connectors. 13. Reposition and install the PCV pipe (for 1.6/1.8 only). 14. Reposition the power steering bracket and install the power steering line bracket bolt (for 1.6/1.8 only). 15. Connect the negative battery cable. Note If an engine rattle noise is heard after removing the filters, refer to SI for further diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory Fluid - M/T: All Technical Service Bulletins Campaign - Transmission Fluid Overfill From Factory SERVICE UPDATE Bulletin No.: 11008A Date: February 01, 2011 Subject: 11008A - Service Update for Inventory and Customer Vehicles - Transmission Fluid Overfill - Drain Excess Fluid - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Manual Transmission (MF3/MZ0) Supercede: The illustration for Step 9 in the Service Procedure has been revised to eliminate confusion on the amount of fluid to remove. Technicians are to remove 0.4L of transmission fluid after allowing the fluid to drain completely from the plug hole. Please discard all copies of bulletin 11008, issued January 2011. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to drain excess transmission fluid on certain 2011 model year Chevrolet Cruze vehicles with manual transmissions (MF3/MZ0). These vehicles may have received more than the required amount of transmission fluid, which could result in a hard shift and reduced fuel economy. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. Parts Information PN 55563377, plug, has been temporarily excluded from RIM. A sufficient number of plugs are being pre-shipped to involved dealers beginning January 21, 2011. The pre-shipped parts can be identified with control "Cruze-Recall", and will be shipped from Lansing, MI via Overnight Delivery. After you have received your preshipment of plugs, if you should still need additional parts, you can order them from General Motors Customer Care and Aftersales (GMCC&A;). Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory > Page 619 2. Remove the front compartment insulator. Refer to Front Compartment Insulator Replacement in SI. Oil Level Plug Shown on Manual Transmission Out of Vehicles Note There are three oil plugs on the manual transmission. There is a fill plug that is located on the top of the transmission below the battery tray. There is also a drain plug on the bottom of the transmission on the driver's side of the vehicle. The oil level plug (1) is located above the drain plug on the driver's side of the vehicle. Refer to the illustration. 3. Locate the oil level plug. 4. Place a basin below the transmission. 5. Place a shop towel or piece of plastic over the frame/front suspension as shown in the illustration. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory > Page 620 6. Remove the oil level plug. 7. Discard the oil level plug. 8. Allow the fluid to drain completely from the plug hole. Caution To preserve fluid quality and avoid harsh transmission shifts, after allowing the fluid to drain completely from the plug hole, remove 0.4L of transmission fluid. 9. Using a syringe and a 7.1mm (9/32 in) rubber hose, remove 0.4L of transmission fluid. 10. Clean all dirt and debris from the transmission oil level plug area. 11. Install a new oil level plug. Tighten Tighten the plug to 17 Nm (12.5 lb ft). 12. Remove the shop towel or plastic from the frame/front suspension. 13. Remove the transmission fluid from the vehicle frame, transmission, suspension and engine. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory > Page 621 14. Install the front compartment insulator. Refer to Front Compartment Insulator Replacement in SI. 15. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory > Page 627 2. Remove the front compartment insulator. Refer to Front Compartment Insulator Replacement in SI. Oil Level Plug Shown on Manual Transmission Out of Vehicles Note There are three oil plugs on the manual transmission. There is a fill plug that is located on the top of the transmission below the battery tray. There is also a drain plug on the bottom of the transmission on the driver's side of the vehicle. The oil level plug (1) is located above the drain plug on the driver's side of the vehicle. Refer to the illustration. 3. Locate the oil level plug. 4. Place a basin below the transmission. 5. Place a shop towel or piece of plastic over the frame/front suspension as shown in the illustration. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory > Page 628 6. Remove the oil level plug. 7. Discard the oil level plug. 8. Allow the fluid to drain completely from the plug hole. Caution To preserve fluid quality and avoid harsh transmission shifts, after allowing the fluid to drain completely from the plug hole, remove 0.4L of transmission fluid. 9. Using a syringe and a 7.1mm (9/32 in) rubber hose, remove 0.4L of transmission fluid. 10. Clean all dirt and debris from the transmission oil level plug area. 11. Install a new oil level plug. Tighten Tighten the plug to 17 Nm (12.5 lb ft). 12. Remove the shop towel or plastic from the frame/front suspension. 13. Remove the transmission fluid from the vehicle frame, transmission, suspension and engine. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory > Page 629 14. Install the front compartment insulator. Refer to Front Compartment Insulator Replacement in SI. 15. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Disassembled Views Camshaft Position Sensor: Locations Disassembled Views Disassembled Views Engine Front Cover And Oil Pump Assembly (1 of 2) 1 - Camshaft Position Actuator Solenoid Valve Bolt 2 - Intake Camshaft Position Actuator Solenoid Valve 3 - Exhaust Camshaft Position Actuator Solenoid Valve 4 - Intake Camshaft Position Sensor Bolt 5 - Intake Camshaft Position Sensor 6 - Intake Camshaft Position Sensor Seal Ring 7 - Engine Front Cover 8 - Engine Front Cover Gasket 9 - Exhaust Camshaft Position Sensor Seal Ring 10 Exhaust Camshaft Position Sensor 11 - Exhaust Camshaft Position Sensor Bolt 12 - Engine Front Cover Oil Gallery Plug 13 - Engine Front Cover Oil Gallery Plug Seal Ring 14 - Oil Pressure Relief Valve Piston 15 - Oil Pressure Relief Valve Spring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 632 16 - Oil Pressure Relief Valve Plug 17 - Engine Front Cover Bolt (M10) 18 - Crankshaft Front Oil Seal 19 - Engine Front Cover Bolt (M6) 20 - Water Drain Plug Seal Ring 21 - Water Drain Plug 22 - Exhaust Camshaft Position Actuator Solenoid Valve Bolt Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 633 Camshaft Position Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Front (LUJ) 1 - Q6E Camshaft Position Actuator Solenoid Valve - Exhaust 2 - B23E Camshaft Position Sensor Exhaust 3 - B37 Engine Oil Pressure Switch 4 - B52A Heated Oxygen Sensor 1 5 - Q42 Turbocharger Wastegate Solenoid Valve 6 - Q2 A/C Compressor Clutch Engine Components - Right Rear (LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 634 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 635 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Open hood. Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 2. Disconnect the camshaft position sensor wiring harness plug (1). Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 3. Remove the camshaft position sensor bolt (3). 4. Remove the camshaft position sensor (2) and the seal ring (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 636 Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 1. Install the camshaft position sensor (2) and the seal ring (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 2. Install the camshaft position sensor bolt (3) and tighten to 8 Nm (71 lb in). Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 3. Connect the camshaft position sensor wiring harness plug (1). 4. After replacement of an camshaft position sensor, use a scan tool to speed up learn function. Refer to Engine Control Module Programming and Setup (LUW, LUJ) (See: Testing and Inspection/Programming and Relearning/Engine Control Module Programming and Setup) 5. Close hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Powertrain Component Views Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Powertrain Component Views Engine Components - Left Rear (LUJ) 1 - B111 Turbocharger Boost Pressure Sensor 2 - T8 Ignition Coil 3 - B68 Knock Sensor (KS) 4 Q38 Throttle Body 5 - B34 Engine Coolant Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Powertrain Component Views > Page 641 Coolant Temperature Sensor/Switch (For Computer): Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components 1 - G105 Engine Compartment - Front Left 2 - G10 Cooling Fan Motor 3 - B34B Engine Coolant Temperature Sensor 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Engine Coolant Temperature Sensor Replacement (Radiator) Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement (Radiator) Engine Coolant Temperature Sensor Replacement (Radiator) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Engine Coolant Temperature Sensor Replacement (Radiator) > Page 644 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement (Water Outlet) Engine Coolant Temperature Sensor Replacement (Water Outlet) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views Crankshaft Position Sensor: Locations Disassembled Views Disassembled Views Engine Block Assembly - 1.4L LDD 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Engine Block 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 649 16 - Oil Pan Bolt 17 - Oil Pan Drain Plug Seal Ring 18 - Oil Pan Drain Plug 19 - Crankshaft Position Sensor Bolt 20 - Crankshaft Position Sensor 21 - Crankshaft Position Sensor Seal Ring 22 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 23 - Crankshaft Position Sensor Reluctor Ring 24 Flywheel Bolt 25 - Engine Flywheel 26 - Crankshaft Rear Oil Seal 27 - Crankshaft Position Sensor Reluctor Ring Bolt 28 - Connecting Rod Bearing Cap Bolt 29 - Connecting Rod Bearing Cap 30 Lower Connecting Rod Bearing 31 - Upper Connecting Rod Bearing 32 - Connecting Rod 33 Piston Pin 34 - Piston 35 - Piston Oil Ring (With oil Ring Spacer) 36 - Lower Compression Ring 37 - Upper Compression Ring Engine Block Assembly - 1.4L LUH and LUJ Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 650 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Cylinder Head 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Baffle 16 - Oil Pan Baffle Bolt 17 - Oil Pan 18 - Oil Pan Bolt 19 - Oil Pan Drain Plug 20 - Crankshaft Position Sensor Bolt 21 - Crankshaft Position Sensor 22 - Crankshaft Position Sensor Seal Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 651 23 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 24 - Piston Oil Nozzle 25 - Crankshaft Position Sensor Reluctor Ring 26 - Crankshaft Position Sensor Reluctor Ring Bolt 27 - Crankshaft Rear Oil Seal 28 - Engine Flywheel (Two-Mass) 29 - Engine Flywheel Bolt 30 - Connecting Rod Bearing Cap Bolt 31 - Connecting Rod Bearing Cap 32 - Lower Connecting Rod Bearing 33 - Upper Connecting Rod Bearing 34 - Connecting Rod 35 - Piston Pin 36 - Piston Pin Retainer 37 - Piston Pin Retainer 38 - Piston 39 - Piston Oil Ring (With Oil Ring Spacer) 40 - Lower Compression Ring 41 - Upper Compression Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 652 Crankshaft Position Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Rear (LUJ) 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 653 Crankshaft Position Sensor: Diagrams Component Connector End Views B26 Crankshaft Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 654 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The crankshaft position sensor system variation learn procedure is required when the following service procedures have been performed, regardless of whether DTC P0315 00 is set: * Engine replacement * Engine control module (ECM) replacement * Crankshaft damper replacement * Crankshaft replacement * Crankshaft Position Sensor Replacement * Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Note: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the crankshaft position sensor system variation learn procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * Crankshaft Position Sensor activity - If there is a crankshaft position sensor condition, refer to the applicable DTC that set. * Camshaft position signal activity - If there is a camshaft position sensor signal condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT) - If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P0315 00, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select the Crankshaft Position System Variation Learn procedure and perform the following: 1. Observe the fuel cut-off for the applicable engine. 2. Block the drive wheels. 3. Set the parking brake. 4. Place the vehicles transmission in Park or Neutral. 5. Turn the air conditioning (A/C) OFF. 6. Cycle the ignition from OFF to ON. 7. Apply and hold the brake pedal for the duration of the procedure. 8. Start and idle the engine. 9. Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 10. Release the throttle when fuel cut-off occurs. ‹› Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC P0315 00 ran and passed, the crankshaft position sensor variation learn procedure is complete. If the scan tool indicates DTC P0315 00 failed or did not run, refer to DTC P0315 (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 5. Turn OFF the ignition for 30 s after the learn procedure is completed successfully. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 655 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Wheels/Vehicle Underbody Component Views Fuel Tank Components 1 - B150 Fuel Tank Pressure Sensor 2 - A7 Fuel Pump and Level Sensor Assembly 3 - Q13 Evaporative Emission (EVAP) Vent Solenoid Valve Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 659 Fuel Level Sensor: Diagrams Component Connector End Views A7 Fuel Pump and Level Sensor Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 660 Fuel Level Sensor: Service and Repair Fuel Sender Assembly Replacement Removal Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning: Refer to Safety Goggles and Fuel Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions/Safety Goggles and Fuel Warning). Caution: Use care while handling the fuel sender to prevent damage and incorrect fuel level readings. 1. Remove the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Tank Fuel Pump Module Replacement). 2. Disconnect the fuel sender assembly wiring harness plugs (1). 3. Unclip the 2 fuel sender retainer pins. 4. Remove the fuel sender assembly (2). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 661 1. Install the fuel sender assembly (2). 2. Connect the fuel sender assembly wiring harness plugs (1). 3. Install the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Tank Fuel Pump Module Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations Wheels/Vehicle Underbody Component Views Fuel Tank Components 1 - B150 Fuel Tank Pressure Sensor 2 - A7 Fuel Pump and Level Sensor Assembly 3 - Q13 Evaporative Emission (EVAP) Vent Solenoid Valve Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 665 Fuel Tank Pressure Sensor: Diagrams Component Connector End Views B150 Fuel Tank Pressure Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Front of Vehicle/Engine Compartment Component Views Right Front of the Vehicle Components 1 of 2 1 - B75B Mass Air Flow/Intake Air Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views Knock Sensor: Locations Disassembled Views Disassembled Views Engine Block Assembly - 1.4L LDD 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Engine Block 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views > Page 673 16 - Oil Pan Bolt 17 - Oil Pan Drain Plug Seal Ring 18 - Oil Pan Drain Plug 19 - Crankshaft Position Sensor Bolt 20 - Crankshaft Position Sensor 21 - Crankshaft Position Sensor Seal Ring 22 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 23 - Crankshaft Position Sensor Reluctor Ring 24 Flywheel Bolt 25 - Engine Flywheel 26 - Crankshaft Rear Oil Seal 27 - Crankshaft Position Sensor Reluctor Ring Bolt 28 - Connecting Rod Bearing Cap Bolt 29 - Connecting Rod Bearing Cap 30 Lower Connecting Rod Bearing 31 - Upper Connecting Rod Bearing 32 - Connecting Rod 33 Piston Pin 34 - Piston 35 - Piston Oil Ring (With oil Ring Spacer) 36 - Lower Compression Ring 37 - Upper Compression Ring Engine Block Assembly - 1.4L LUH and LUJ Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views > Page 674 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Cylinder Head 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Baffle 16 - Oil Pan Baffle Bolt 17 - Oil Pan 18 - Oil Pan Bolt 19 - Oil Pan Drain Plug 20 - Crankshaft Position Sensor Bolt 21 - Crankshaft Position Sensor 22 - Crankshaft Position Sensor Seal Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views > Page 675 23 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 24 - Piston Oil Nozzle 25 - Crankshaft Position Sensor Reluctor Ring 26 - Crankshaft Position Sensor Reluctor Ring Bolt 27 - Crankshaft Rear Oil Seal 28 - Engine Flywheel (Two-Mass) 29 - Engine Flywheel Bolt 30 - Connecting Rod Bearing Cap Bolt 31 - Connecting Rod Bearing Cap 32 - Lower Connecting Rod Bearing 33 - Upper Connecting Rod Bearing 34 - Connecting Rod 35 - Piston Pin 36 - Piston Pin Retainer 37 - Piston Pin Retainer 38 - Piston 39 - Piston Oil Ring (With Oil Ring Spacer) 40 - Lower Compression Ring 41 - Upper Compression Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views > Page 676 Knock Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Left Rear (LUJ) 1 - B111 Turbocharger Boost Pressure Sensor 2 - T8 Ignition Coil 3 - B68 Knock Sensor (KS) 4 Q38 Throttle Body 5 - B34 Engine Coolant Temperature Sensor Lower Rear of the Engine Components 1 of 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views > Page 677 1 - B68 Knock Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 678 Knock Sensor: Description and Operation Knock Sensor System Description Circuit/System Description The knock sensor system enables the engine control module (ECM) to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The ECM uses the knock sensor system to test for abnormal engine noise that may indicate detonation, also known as spark knock. Sensor Description This knock sensor system uses one or two flat response dual-wire sensors. The sensor uses piezo-electric crystal technology that produces an alternating current (AC) voltage signal of varying amplitude and frequency based on the engine vibration or noise level. The amplitude and frequency are dependant upon the level of knock that the knock sensor detects. The ECM receives the knock sensor signal through 2 isolated signal circuits. If the ECM has determined that knock is present, it will retard the ignition timing to attempt to reduce the knock. The ECM is capable of controlling spark retard on an individual cylinder basis. The ECM will always try to work back to a zero compensation level, or no spark retard. knock sensor diagnostics are calibrated to detect faults with the knock sensor circuitry inside the ECM, the knock sensor wiring, or the knock sensor voltage output. Some diagnostics are also calibrated to detect constant noise from an outside influence such as a loose/damaged component or excessive mechanical engine noise. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 679 Knock Sensor: Service and Repair Knock Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Disassembled Views Manifold Pressure/Vacuum Sensor: Locations Disassembled Views Disassembled Views Intake Manifold Assembly - 1.4L LUH and LUJ 1 - Fuel Injector Fuel Rail 2 - Fuel Injector Fuel Rail Bolt 3 - Manifold Absolute Pressure Sensor 4 Manifold Absolute Pressure Sensor Bolt 5 - Evaporative Emission Canister Purge Solenoid Valve 6 - Intake Manifold 7 - Throttle Body Seal Ring 8 - Throttle Body 9 - Throttle Body Bolt 10 - Intake Manifold Gasket Intake Manifold Assembly - 1.4L LDD Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Disassembled Views > Page 684 1 - Intake Manifold Sealings 2 - Intake Manifold (With Intake Manifold Runner and Intake Manifold Runner Valve) 3 - Throttle Body Bolt 4 - Throttle Body 5 - Throttle Body Seal Ring 6 - Fuel Injection Fuel Rail Bolt 7 - Evaporative Emission Canister Purge Solenoid Valve 8 - Evaporative Emission Canister Purge Solenoid Valve Rubber 9 - Evaporative Emission Canister Purge Solenoid Valve Bracket Bolt 10 - Evaporative Emission Canister Purge Solenoid Valve Bracket 11 - Fuel Injection Fuel Rail 12 - Fuel Injector Retainer Clamp 13 - Fuel Injector 14 - Manifold Absolute Pressure Sensor Bolt 15 - Manifold Absolute Pressure Sensor 16 - Manifold Absolute Pressure Sensor Seal Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Disassembled Views > Page 685 Manifold Pressure/Vacuum Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Rear (LUJ) 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 686 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Disassembled Views Oxygen Sensor: Locations Disassembled Views Disassembled Views Exhaust Side - 1.4L LUH and LUJ 1 - Positive Crankcase Ventilation Pipe Assembly 2 - Exhaust Manifold Gasket 3 - Turbo Charger Oil Feed Pipe Hollow Screw 4 - Turbo Charger Oil Feed Pipe 5 - Turbo Charger Oil Feed Pipe Bolt 6 - Oil Cooler Coolant Outlet Hose 7 - Oil Cooler Coolant Outlet Hose Clamp 8 - Oil Cooler Coolant Feed Pipe Bolt 9 - Oil Cooler Coolant Feed Pipe 10 - Engine Oil Cooler Assembly 11 - Catalytic Converter Bracket 12 - Catalytic Converter to Catalytic Converter Bracket Nut 13 - Turbocharger Coolant Return Pipe 14 - Turbocharger Coolant Feed Pipe Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Disassembled Views > Page 691 15 - Turbocharger Coolant Feed Pipe Hollow Screw 16 - Heated Oxygen Sensor 1 17 - Catalytic Converter 18 - Catalytic Converter Heat Shield 19 - Catalytic Converter Heat Shield Bolt 20 - Catalytic Converter Seal 21 - Catalytic Converter V-Clamp 22 - Turbocharger Oil Return Pipe 23 Turbocharger Oil Return Pipe Bolt 24 - Exhaust Manifold Heat Shield 25 - Exhaust Manifold Heat Shield Bolt 26 - Turbocharger (with Exhaust Manifold) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Disassembled Views > Page 692 Oxygen Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Front (LUJ) 1 - Q6E Camshaft Position Actuator Solenoid Valve - Exhaust 2 - B23E Camshaft Position Sensor Exhaust 3 - B37 Engine Oil Pressure Switch 4 - B52A Heated Oxygen Sensor 1 5 - Q42 Turbocharger Wastegate Solenoid Valve 6 - Q2 A/C Compressor Clutch Engine Components - Right Rear (LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Disassembled Views > Page 693 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Caution > Page 696 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Caution > Page 697 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Sensor 1 Heated Oxygen Sensor Replacement - Sensor 1 (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Sensor 1 > Page 700 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Sensor 2 Heated Oxygen Sensor Replacement - Sensor 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair Transmission Position Switch/Sensor: Service and Repair Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Special Tools DT-41229 - Manual Shaft Pin Installer For equivalent regional tools, refer to Special Tools (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Tools and Equipment). Removal Procedure 1. Remove the control valve body. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 2. Remove the manual shaft detent lever hub pin (1) using a pry bar and pliers. 3. Remove and DISCARD the manual shift shaft pin (5). 4. Remove the manual shaft (2). 5. Disconnect the actuator rod (3) from the detent lever assembly. Do not remove the actuator rod from the transmission case. 6. Remove the manual shaft detent (with shift position switch) lever assembly (4). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Page 704 1. Connect the actuator rod (3) to the detent lever assembly. 2. Install the manual shaft detent (with shift position switch) lever assembly (4). 3. Install the manual shaft (2). 4. Install the manual shaft detent lever hub pin (1) to height of 7.9 mm (0.38 in) (b). Caution: Use J 41229 to install the manual shaft pin at the correct height in order to properly secure the manual shaft. If you install the pin too deep, the case bore may crack. 5. Install the NEW manual shift shaft pin (5) using DT-41229 - pin installer. Use a NEW pin to ensure proper engagement with the case. 6. Inspect pin installed height is within 7.2-8.2 mm (0.28-0.32 in) (a). 7. Install the control valve body. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 8. Perform the transmission adaptive values learn procedure. Refer to Transmission Adaptive Values Learn (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 709 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views B107 Accelerator Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 710 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Right Front of the Vehicle Components 1 of 2 1 - B75B Mass Air Flow/Intake Air Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 714 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor Replacement (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair Fuel Pressure Sensor/Switch: Service and Repair Fuel Pressure Sensor Replacement Removal Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning: Refer to Safety Goggles and Fuel Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions/Safety Goggles and Fuel Warning). 1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the fuel pressure sensor wiring harness plug (2) from the fuel pressure sensor (1). 4. Remove the fuel pressure sensor (1) from the fuel pressure relief valve (2). 5. Remove the fuel pressure sensor seal ring (3). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Page 718 Installation Procedure 1. Install a NEW fuel pressure sensor seal ring (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the fuel pressure sensor (1) to the fuel pressure relief valve (2) and tighten to 19 Nm (14 lb ft). 3. Plug the fuel pressure sensor wiring harness plug (2) to the fuel pressure sensor (1). 4. Lower the vehicle. 5. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations Oil Pressure Switch (For Fuel Pump): Locations Disassembled Views Cylinder Head Assembly 1 - Camshaft Cover 2 - Oil Level Indicator 3 - Camshaft Cover Bolt 4 - Oil Filler Cap 5 - Oil Filler Cap Seal Ring 6 - Camshaft Cover Gasket 7 - Camshaft Bearing Cap Bolt 8 - Camshaft Bearing Cap 9 - Cylinder Head Bolt 10 - Valve Keys 11 - Valve Spring Retainer 12 - Valve Spring 13 Engine Lift Bracket Left Side 14 - Engine Lift Bracket Bolt 15 - Cylinder Head 16 - Intake Valve Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 722 17 - Exhaust Valve 18 - Engine Lift Bracket 19 - Engine Lift Bracket Bolt 20 - Engine Lift Bracket 21 - Engine Lift Bracket Bolt 22 - Oil Pressure Indicator Switch 23 - Oil Pressure Indicator Switch Seal Ring 24 - Hydraulic Valve Lash Adjuster 25 - Hydraulic Valve Lash Adjuster Arm 26 - Exhaust Camshaft 27 - Intake Camshaft Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 723 Oil Pressure Switch (For Fuel Pump): Service and Repair Engine Oil Pressure Indicator Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations Turbo Boost Sensor: Locations Powertrain Component Views Engine Components - Left Rear (LUJ) 1 - B111 Turbocharger Boost Pressure Sensor 2 - T8 Ignition Coil 3 - B68 Knock Sensor (KS) 4 Q38 Throttle Body 5 - B34 Engine Coolant Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle Camshaft Position Sensor: Customer Interest Engine - Lack of Power with Multiple DTCs or Rattle TECHNICAL Bulletin No.: 10-06-04-016 Date: December 20, 2010 Subject: Engine Lack of Power with DTCs P0011, P0014, P000A, P000B, P0012, P0015 or Engine Rattle Noise (Remove Oil Filters from Intake and Exhaust Camshaft Position Actuator Solenoid Valves) Models: 2008-2011 Chevrolet Aveo 2011 Chevrolet Cruze (US and Canada) 2009-2011 Chevrolet Cruze (Export Only) 2008-2009 Pontiac G3, Wave 2008-2009 Saturn Astra Condition Some customers may comment on lack of power with the following DTCs or an engine rattle noise from the sprockets. Cruze GEN3 1.6/1.8D - P0011: Intake Camshaft Position (CMP) System Performance - P0014: Exhaust Camshaft Position (CMP) System Performance - P000A: Intake Camshaft Position System Slow Response - P000B: Exhaust Camshaft Position System Slow Response Aveo GEN3 1.4D - P0012: Intake Camshaft Position (CMP) System Performance Bank 1-Retarded - P0015: Exhaust Camshaft Position (CMP) System Performance Bank 1-Retarded Aveo/G3/Wave Gen3 1.6D - P0011: Intake Camshaft Position (CMP) System Performance Bank 1 - P0014: Exhaust Camshaft Position (CMP) System Performance Bank 1 Correction Remove four oil filters from the intake and exhaust camshaft position actuator solenoid valves. 1. Open the hood. 2. Disconnect the negative battery cable. 3. Disconnect the camshaft position actuator solenoid valve connectors. 4. Remove the power steering line bracket bolt and reposition the bracket (for 1.6/1.8L only). 5. Disconnect PCV pipe and reposition (for 1.6/1.8L only). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 736 6. Remove the camshaft position actuator solenoid valve bolts. 7. Remove the camshaft position actuator solenoid valves and seals. 8. Check whether the filter is broken or not (1). 9. Remove the four filters (intake and exhaust). 1. Broken Filter: Remove filter with a blunt tool. 2. Unbroken Filter 1. Locate the filter hinge between the holes. 2. Cut the filter hinge slightly. Caution Do not scratch the valve surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 737 3. Remove the filter with a blunt tool. 10. Install the camshaft position actuator solenoid valves and seals. Coat the seal with clean engine oil prior to installation. 11. Install the camshaft position actuator solenoid valve bolts. Tighten Tighten the bolts to 6 Nm (53 lb in). 12. Connect the camshaft position actuator solenoid valve connectors. 13. Reposition and install the PCV pipe (for 1.6/1.8 only). 14. Reposition the power steering bracket and install the power steering line bracket bolt (for 1.6/1.8 only). 15. Connect the negative battery cable. Note If an engine rattle noise is heard after removing the filters, refer to SI for further diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle Camshaft Position Sensor: All Technical Service Bulletins Engine - Lack of Power with Multiple DTCs or Rattle TECHNICAL Bulletin No.: 10-06-04-016 Date: December 20, 2010 Subject: Engine Lack of Power with DTCs P0011, P0014, P000A, P000B, P0012, P0015 or Engine Rattle Noise (Remove Oil Filters from Intake and Exhaust Camshaft Position Actuator Solenoid Valves) Models: 2008-2011 Chevrolet Aveo 2011 Chevrolet Cruze (US and Canada) 2009-2011 Chevrolet Cruze (Export Only) 2008-2009 Pontiac G3, Wave 2008-2009 Saturn Astra Condition Some customers may comment on lack of power with the following DTCs or an engine rattle noise from the sprockets. Cruze GEN3 1.6/1.8D - P0011: Intake Camshaft Position (CMP) System Performance - P0014: Exhaust Camshaft Position (CMP) System Performance - P000A: Intake Camshaft Position System Slow Response - P000B: Exhaust Camshaft Position System Slow Response Aveo GEN3 1.4D - P0012: Intake Camshaft Position (CMP) System Performance Bank 1-Retarded - P0015: Exhaust Camshaft Position (CMP) System Performance Bank 1-Retarded Aveo/G3/Wave Gen3 1.6D - P0011: Intake Camshaft Position (CMP) System Performance Bank 1 - P0014: Exhaust Camshaft Position (CMP) System Performance Bank 1 Correction Remove four oil filters from the intake and exhaust camshaft position actuator solenoid valves. 1. Open the hood. 2. Disconnect the negative battery cable. 3. Disconnect the camshaft position actuator solenoid valve connectors. 4. Remove the power steering line bracket bolt and reposition the bracket (for 1.6/1.8L only). 5. Disconnect PCV pipe and reposition (for 1.6/1.8L only). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 743 6. Remove the camshaft position actuator solenoid valve bolts. 7. Remove the camshaft position actuator solenoid valves and seals. 8. Check whether the filter is broken or not (1). 9. Remove the four filters (intake and exhaust). 1. Broken Filter: Remove filter with a blunt tool. 2. Unbroken Filter 1. Locate the filter hinge between the holes. 2. Cut the filter hinge slightly. Caution Do not scratch the valve surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 744 3. Remove the filter with a blunt tool. 10. Install the camshaft position actuator solenoid valves and seals. Coat the seal with clean engine oil prior to installation. 11. Install the camshaft position actuator solenoid valve bolts. Tighten Tighten the bolts to 6 Nm (53 lb in). 12. Connect the camshaft position actuator solenoid valve connectors. 13. Reposition and install the PCV pipe (for 1.6/1.8 only). 14. Reposition the power steering bracket and install the power steering line bracket bolt (for 1.6/1.8 only). 15. Connect the negative battery cable. Note If an engine rattle noise is heard after removing the filters, refer to SI for further diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Disassembled Views Camshaft Position Sensor: Locations Disassembled Views Disassembled Views Engine Front Cover And Oil Pump Assembly (1 of 2) 1 - Camshaft Position Actuator Solenoid Valve Bolt 2 - Intake Camshaft Position Actuator Solenoid Valve 3 - Exhaust Camshaft Position Actuator Solenoid Valve 4 - Intake Camshaft Position Sensor Bolt 5 - Intake Camshaft Position Sensor 6 - Intake Camshaft Position Sensor Seal Ring 7 - Engine Front Cover 8 - Engine Front Cover Gasket 9 - Exhaust Camshaft Position Sensor Seal Ring 10 Exhaust Camshaft Position Sensor 11 - Exhaust Camshaft Position Sensor Bolt 12 - Engine Front Cover Oil Gallery Plug 13 - Engine Front Cover Oil Gallery Plug Seal Ring 14 - Oil Pressure Relief Valve Piston 15 - Oil Pressure Relief Valve Spring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 747 16 - Oil Pressure Relief Valve Plug 17 - Engine Front Cover Bolt (M10) 18 - Crankshaft Front Oil Seal 19 - Engine Front Cover Bolt (M6) 20 - Water Drain Plug Seal Ring 21 - Water Drain Plug 22 - Exhaust Camshaft Position Actuator Solenoid Valve Bolt Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 748 Camshaft Position Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Front (LUJ) 1 - Q6E Camshaft Position Actuator Solenoid Valve - Exhaust 2 - B23E Camshaft Position Sensor Exhaust 3 - B37 Engine Oil Pressure Switch 4 - B52A Heated Oxygen Sensor 1 5 - Q42 Turbocharger Wastegate Solenoid Valve 6 - Q2 A/C Compressor Clutch Engine Components - Right Rear (LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 749 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 750 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Open hood. Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 2. Disconnect the camshaft position sensor wiring harness plug (1). Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 3. Remove the camshaft position sensor bolt (3). 4. Remove the camshaft position sensor (2) and the seal ring (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 751 Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 1. Install the camshaft position sensor (2) and the seal ring (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 2. Install the camshaft position sensor bolt (3) and tighten to 8 Nm (71 lb in). Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 3. Connect the camshaft position sensor wiring harness plug (1). 4. After replacement of an camshaft position sensor, use a scan tool to speed up learn function. Refer to Engine Control Module Programming and Setup (LUW, LUJ) (See: Testing and Inspection/Programming and Relearning/Engine Control Module Programming and Setup) 5. Close hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views Crankshaft Position Sensor: Locations Disassembled Views Disassembled Views Engine Block Assembly - 1.4L LDD 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Engine Block 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 756 16 - Oil Pan Bolt 17 - Oil Pan Drain Plug Seal Ring 18 - Oil Pan Drain Plug 19 - Crankshaft Position Sensor Bolt 20 - Crankshaft Position Sensor 21 - Crankshaft Position Sensor Seal Ring 22 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 23 - Crankshaft Position Sensor Reluctor Ring 24 Flywheel Bolt 25 - Engine Flywheel 26 - Crankshaft Rear Oil Seal 27 - Crankshaft Position Sensor Reluctor Ring Bolt 28 - Connecting Rod Bearing Cap Bolt 29 - Connecting Rod Bearing Cap 30 Lower Connecting Rod Bearing 31 - Upper Connecting Rod Bearing 32 - Connecting Rod 33 Piston Pin 34 - Piston 35 - Piston Oil Ring (With oil Ring Spacer) 36 - Lower Compression Ring 37 - Upper Compression Ring Engine Block Assembly - 1.4L LUH and LUJ Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 757 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Cylinder Head 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Baffle 16 - Oil Pan Baffle Bolt 17 - Oil Pan 18 - Oil Pan Bolt 19 - Oil Pan Drain Plug 20 - Crankshaft Position Sensor Bolt 21 - Crankshaft Position Sensor 22 - Crankshaft Position Sensor Seal Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 758 23 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 24 - Piston Oil Nozzle 25 - Crankshaft Position Sensor Reluctor Ring 26 - Crankshaft Position Sensor Reluctor Ring Bolt 27 - Crankshaft Rear Oil Seal 28 - Engine Flywheel (Two-Mass) 29 - Engine Flywheel Bolt 30 - Connecting Rod Bearing Cap Bolt 31 - Connecting Rod Bearing Cap 32 - Lower Connecting Rod Bearing 33 - Upper Connecting Rod Bearing 34 - Connecting Rod 35 - Piston Pin 36 - Piston Pin Retainer 37 - Piston Pin Retainer 38 - Piston 39 - Piston Oil Ring (With Oil Ring Spacer) 40 - Lower Compression Ring 41 - Upper Compression Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 759 Crankshaft Position Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Rear (LUJ) 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 760 Crankshaft Position Sensor: Diagrams Component Connector End Views B26 Crankshaft Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 761 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The crankshaft position sensor system variation learn procedure is required when the following service procedures have been performed, regardless of whether DTC P0315 00 is set: * Engine replacement * Engine control module (ECM) replacement * Crankshaft damper replacement * Crankshaft replacement * Crankshaft Position Sensor Replacement * Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Note: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the crankshaft position sensor system variation learn procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * Crankshaft Position Sensor activity - If there is a crankshaft position sensor condition, refer to the applicable DTC that set. * Camshaft position signal activity - If there is a camshaft position sensor signal condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT) - If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P0315 00, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select the Crankshaft Position System Variation Learn procedure and perform the following: 1. Observe the fuel cut-off for the applicable engine. 2. Block the drive wheels. 3. Set the parking brake. 4. Place the vehicles transmission in Park or Neutral. 5. Turn the air conditioning (A/C) OFF. 6. Cycle the ignition from OFF to ON. 7. Apply and hold the brake pedal for the duration of the procedure. 8. Start and idle the engine. 9. Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 10. Release the throttle when fuel cut-off occurs. ‹› Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC P0315 00 ran and passed, the crankshaft position sensor variation learn procedure is complete. If the scan tool indicates DTC P0315 00 failed or did not run, refer to DTC P0315 (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 5. Turn OFF the ignition for 30 s after the learn procedure is completed successfully. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 762 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair Key and Lock Cylinder Coding Ignition Lock Cylinder The ignition lock cylinder uses 8 key cut positions, 1-8. The tumbler positions are staggered from side to side, four on one side and four on the other. Note: The tumblers (5) are not self-retaining and must be held in place if the key is not fully inserted into the lock cylinder or until the cylinder (2) is assembled into the case assembly (8). 1. Hold the cylinder assembly (2) so that the retainer pin pocket is facing upward. 2. Insert one tumbler spring (4) into each of the 4 spring wells. 3. The first tumbler (5) to be loaded will be the first key cut position, the first number in the key code. Install the first tumbler in the slot nearest the head of the lock cylinder. Install the remaining tumblers following the key code into the slots at the key cut positions 3, 5 and 7. It may be necessary to move the sidebar (already pre-assembled into the cylinder assembly) out slightly to fully install the tumbler into the correct slot. 4. Check the correct loading by holding the tumblers (5) in position and fully inserting the key into the cylinder assembly (2). All tumblers and the sidebar should be flushed with the outside diameter of the cylinder assembly body. 5. Rotate the cylinder assembly (2) so that the retention lug is facing upward and then remove the key, always holding all tumblers so they do not fall out. 6. Insert one tumbler spring (4) into each of the 4 spring wells. 7. The first tumbler (5) to be loaded will be the second key cut position, the second number in the key code. Install the tumbler in the slot nearest the head of the lock cylinder. Install the remaining tumblers following the key code into the slots at the key cut positions 4, 6 and 8. 8. Check for the correct loading by holding the tumblers (5) in position and fully inserting the key into the cylinder assembly (2). 9. Lightly lubricate the tumbler (5) surfaces and the small detent recess on the side of the cylinder assembly (2) using the lubrication provided. 10. With the key fully inserted, rotate the cylinder assembly so that the side with the retaining pin (7) pocket is facing upward. 11. Insert the retaining pin spring (6) and then retaining pin (7) into the pocket located behind the 4 tumblers. The retaining pin spring and retaining pin are not self-retaining and must be held in place until the cylinder is installed into the case assembly (8). 12. With the key fully inserted into the cylinder assembly and the retaining pin (7) fully depressed into the cylinder, align the retainer lug on the cylinder with the groove on the inside diameter of the case assembly (8). This groove extends the full length of the case assembly. 13. Install the cylinder assembly into the case assembly (8) being very careful to hold the retainer pin spring (6) and retainer pin (7) in the cylinder until they enter into the case assembly. With the cylinder fully inserted into the case assembly, rotate the cylinder counterclockwise until the retainer pin (7) snaps into place limiting the rotation of the cylinder assembly. 14. With the cylinder assembly in the Off-Lock position, insert the detent rod (1) into the hole in the side of the case assembly (8). Install the anti-rattle spring (3) into the case assembly over the detent spring. The anti-rattle spring should capture the detent ball and spring in the case assembly. Make sure both ends of the anti-rattle spring (3) are fully seated, pressed into, the case assembly. 15. With the cylinder assembly in the Off-Lock position, insert the detent rod (1) into the hole in the side of the case assembly (8). Install the anti-rattle spring (3) into the case assembly over the detent spring. The anti-rattle spring should capture the detent ball and spring in the case assembly. Make sure both ends of the anti-rattle spring (3) are fully seated, pressed into, the case assembly. Front Side Door Lock Cylinder Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Page 767 1. Rotate the cylinder (8) so that the side with the tumbler spring wells faces up. 2. Insert the tumbler springs (4) into the 4 spring wells. 3. Install the tumbler (10) for key cut position 3 in the slot closest to the cylinder head. Install the remaining tumblers, key cut positions 5, 7 and 9, following the key code and same process. Press the tumblers in place until they are secure. 4. Check the correct loading of the tumblers by inserting the key into the cylinder. All tumblers should be flushed with the lock cylinder body. 5. Turn the cylinder so the side with the other tumbler spring wells faces up. 6. Insert the tumbler springs (4) into the 4 spring wells. 7. The first tumbler closest to the head of the lock cylinder to be loaded will be the fourth key cut position. Install the remaining tumblers for key cut positions 6, 8 and 10. Press the tumblers in place until they are secure. 8. Check the correct loading of the tumblers by inserting the key into the cylinder. All of the tumblers should be flushed with the lock cylinder body. 9. Apply lubricant to the cylinder body and tumbler surfaces along with a small amount in the head of the cylinder using the supplied lubricant. 10. Install the retainer (5) into the spring wells in the head of the lock cylinder. 11. Snap the shutter (7) into the cylinder. 12. Assemble the cylinder into the case (3). 13. Align dimples of the cylinder cap (6) with the 4 recesses in the cap. Secure by pressing the cap into place with light hand pressure. 14. Assemble the rod clip (2) to the lever (1). 15. Assemble the lever (1) to the lock. Use driver unit (11) to retain the lever assembly. 16. Assemble the gasket to the lock. 17. Insert the key into the lock and function the lock to check for proper assembly and smooth operation. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views Knock Sensor: Locations Disassembled Views Disassembled Views Engine Block Assembly - 1.4L LDD 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Engine Block 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views > Page 772 16 - Oil Pan Bolt 17 - Oil Pan Drain Plug Seal Ring 18 - Oil Pan Drain Plug 19 - Crankshaft Position Sensor Bolt 20 - Crankshaft Position Sensor 21 - Crankshaft Position Sensor Seal Ring 22 Crankshaft Bearing Cap Tie Plate Bolt (M8) 23 - Crankshaft Position Sensor Reluctor Ring 24 Flywheel Bolt 25 - Engine Flywheel 26 - Crankshaft Rear Oil Seal 27 - Crankshaft Position Sensor Reluctor Ring Bolt 28 - Connecting Rod Bearing Cap Bolt 29 - Connecting Rod Bearing Cap 30 Lower Connecting Rod Bearing 31 - Upper Connecting Rod Bearing 32 - Connecting Rod 33 Piston Pin 34 - Piston 35 - Piston Oil Ring (With oil Ring Spacer) 36 - Lower Compression Ring 37 - Upper Compression Ring Engine Block Assembly - 1.4L LUH and LUJ Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views > Page 773 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Cylinder Head 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Baffle 16 - Oil Pan Baffle Bolt 17 - Oil Pan 18 - Oil Pan Bolt 19 - Oil Pan Drain Plug 20 - Crankshaft Position Sensor Bolt 21 - Crankshaft Position Sensor 22 - Crankshaft Position Sensor Seal Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views > Page 774 23 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 24 - Piston Oil Nozzle 25 - Crankshaft Position Sensor Reluctor Ring 26 - Crankshaft Position Sensor Reluctor Ring Bolt 27 - Crankshaft Rear Oil Seal 28 - Engine Flywheel (Two-Mass) 29 - Engine Flywheel Bolt 30 - Connecting Rod Bearing Cap Bolt 31 - Connecting Rod Bearing Cap 32 - Lower Connecting Rod Bearing 33 - Upper Connecting Rod Bearing 34 - Connecting Rod 35 - Piston Pin 36 - Piston Pin Retainer 37 - Piston Pin Retainer 38 - Piston 39 - Piston Oil Ring (With Oil Ring Spacer) 40 - Lower Compression Ring 41 - Upper Compression Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views > Page 775 Knock Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Left Rear (LUJ) 1 - B111 Turbocharger Boost Pressure Sensor 2 - T8 Ignition Coil 3 - B68 Knock Sensor (KS) 4 Q38 Throttle Body 5 - B34 Engine Coolant Temperature Sensor Lower Rear of the Engine Components 1 of 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views > Page 776 1 - B68 Knock Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 777 Knock Sensor: Description and Operation Knock Sensor System Description Circuit/System Description The knock sensor system enables the engine control module (ECM) to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The ECM uses the knock sensor system to test for abnormal engine noise that may indicate detonation, also known as spark knock. Sensor Description This knock sensor system uses one or two flat response dual-wire sensors. The sensor uses piezo-electric crystal technology that produces an alternating current (AC) voltage signal of varying amplitude and frequency based on the engine vibration or noise level. The amplitude and frequency are dependant upon the level of knock that the knock sensor detects. The ECM receives the knock sensor signal through 2 isolated signal circuits. If the ECM has determined that knock is present, it will retard the ignition timing to attempt to reduce the knock. The ECM is capable of controlling spark retard on an individual cylinder basis. The ECM will always try to work back to a zero compensation level, or no spark retard. knock sensor diagnostics are calibrated to detect faults with the knock sensor circuitry inside the ECM, the knock sensor wiring, or the knock sensor voltage output. Some diagnostics are also calibrated to detect constant noise from an outside influence such as a loose/damaged component or excessive mechanical engine noise. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 778 Knock Sensor: Service and Repair Knock Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations Passenger Compartment/Roof Component Views Left Rear of the Passenger Compartment Components 1 of 2 1 - F105L Roof Rail Air Bag - Left 2 - B63LR Side Impact Sensor - Left Rear 3 - B5LR Wheel Speed Sensor - Left Rear 4 - G309 Panel Rear - Left 5 - G401 Panel Rear - Left Left Side of the Passenger Compartment Components Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 783 1 - B63LF Side Impact Sensor - Left Front 2 - F112D Seat Belt Retractor Pretensioner - Driver Right Rear of the Passenger Compartment Components 1 of 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 784 1 - T3 Audio Amplifier 2 - P19AA Speaker - Right Subwoofer 3 - X1 Audio Amplifier X1 4 - X2 Audio Amplifier X2 5 - X3 Audio Amplifier X3 6 - B63RR Side Impact Sensor - Right Rear Right Side of the Passenger Compartment Components 3 of 3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 785 1 - F112P Seat Belt Retractor Pretensioner - Passenger 2 - B63RF Side Impact Sensor - Right Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 786 Impact Sensor: Diagrams Component Connector End Views B59L Front Impact Sensor - Left B59R Front Impact Sensor - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 787 B63LF Side Impact Sensor - Left Front B63LR Side Impact Sensor - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 788 B63RF Side Impact Sensor - Right Front B63RR Side Impact Sensor - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 789 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Side Impact Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement Inflatable Restraint Side Impact Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Side Impact Sensor Replacement > Page 792 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Side Impact Sensor Replacement > Page 793 Impact Sensor: Service and Repair Front End Inflatable Restraint Discriminating Sensor Replacement Front End Inflatable Restraint Discriminating Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams Seat Belt Buckle Switch: Diagrams Component Connector End Views B88D Seat Belt Switch - Driver B88P Seat Belt Switch - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 797 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Inflatable Restraint Front Passenger Presence Sensor Replacement Seat Occupant Sensor: Service and Repair Inflatable Restraint Front Passenger Presence Sensor Replacement Inflatable Restraint Front Passenger Presence Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Inflatable Restraint Front Passenger Presence Sensor Replacement > Page 804 Seat Occupant Sensor: Service and Repair Inflatable Restraint Front Passenger Presence Module Replacement Inflatable Restraint Front Passenger Presence Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Locations Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Side of the Engine Compartment Components 2 of 2 1 - B18 Battery Current Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Locations > Page 809 Battery Current Sensor: Diagrams Component Connector End Views B18 Battery Current Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Locations > Page 810 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Open the hood. 2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Remove the battery ground cable nut (1). 4. Remove the battery negative cable (2). 5. Disconnect the wiring harness current sensor plug (4). 6. Remove the current sensor (5) from the battery tray. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Locations > Page 811 7. Remove the current sensor (2) from the battery negative cable (1). Installation Procedure 1. Install the current sensor (2) to the battery negative cable (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Locations > Page 812 2. Install the current sensor (5) to the battery tray. 3. Connect the wiring harness current sensor plug (4). 4. Install the battery negative cable (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the battery ground cable nut (1) and tighten to 9 Nm (80 lb in). 6. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 7. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair Key and Lock Cylinder Coding Ignition Lock Cylinder The ignition lock cylinder uses 8 key cut positions, 1-8. The tumbler positions are staggered from side to side, four on one side and four on the other. Note: The tumblers (5) are not self-retaining and must be held in place if the key is not fully inserted into the lock cylinder or until the cylinder (2) is assembled into the case assembly (8). 1. Hold the cylinder assembly (2) so that the retainer pin pocket is facing upward. 2. Insert one tumbler spring (4) into each of the 4 spring wells. 3. The first tumbler (5) to be loaded will be the first key cut position, the first number in the key code. Install the first tumbler in the slot nearest the head of the lock cylinder. Install the remaining tumblers following the key code into the slots at the key cut positions 3, 5 and 7. It may be necessary to move the sidebar (already pre-assembled into the cylinder assembly) out slightly to fully install the tumbler into the correct slot. 4. Check the correct loading by holding the tumblers (5) in position and fully inserting the key into the cylinder assembly (2). All tumblers and the sidebar should be flushed with the outside diameter of the cylinder assembly body. 5. Rotate the cylinder assembly (2) so that the retention lug is facing upward and then remove the key, always holding all tumblers so they do not fall out. 6. Insert one tumbler spring (4) into each of the 4 spring wells. 7. The first tumbler (5) to be loaded will be the second key cut position, the second number in the key code. Install the tumbler in the slot nearest the head of the lock cylinder. Install the remaining tumblers following the key code into the slots at the key cut positions 4, 6 and 8. 8. Check for the correct loading by holding the tumblers (5) in position and fully inserting the key into the cylinder assembly (2). 9. Lightly lubricate the tumbler (5) surfaces and the small detent recess on the side of the cylinder assembly (2) using the lubrication provided. 10. With the key fully inserted, rotate the cylinder assembly so that the side with the retaining pin (7) pocket is facing upward. 11. Insert the retaining pin spring (6) and then retaining pin (7) into the pocket located behind the 4 tumblers. The retaining pin spring and retaining pin are not self-retaining and must be held in place until the cylinder is installed into the case assembly (8). 12. With the key fully inserted into the cylinder assembly and the retaining pin (7) fully depressed into the cylinder, align the retainer lug on the cylinder with the groove on the inside diameter of the case assembly (8). This groove extends the full length of the case assembly. 13. Install the cylinder assembly into the case assembly (8) being very careful to hold the retainer pin spring (6) and retainer pin (7) in the cylinder until they enter into the case assembly. With the cylinder fully inserted into the case assembly, rotate the cylinder counterclockwise until the retainer pin (7) snaps into place limiting the rotation of the cylinder assembly. 14. With the cylinder assembly in the Off-Lock position, insert the detent rod (1) into the hole in the side of the case assembly (8). Install the anti-rattle spring (3) into the case assembly over the detent spring. The anti-rattle spring should capture the detent ball and spring in the case assembly. Make sure both ends of the anti-rattle spring (3) are fully seated, pressed into, the case assembly. 15. With the cylinder assembly in the Off-Lock position, insert the detent rod (1) into the hole in the side of the case assembly (8). Install the anti-rattle spring (3) into the case assembly over the detent spring. The anti-rattle spring should capture the detent ball and spring in the case assembly. Make sure both ends of the anti-rattle spring (3) are fully seated, pressed into, the case assembly. Front Side Door Lock Cylinder Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Page 817 1. Rotate the cylinder (8) so that the side with the tumbler spring wells faces up. 2. Insert the tumbler springs (4) into the 4 spring wells. 3. Install the tumbler (10) for key cut position 3 in the slot closest to the cylinder head. Install the remaining tumblers, key cut positions 5, 7 and 9, following the key code and same process. Press the tumblers in place until they are secure. 4. Check the correct loading of the tumblers by inserting the key into the cylinder. All tumblers should be flushed with the lock cylinder body. 5. Turn the cylinder so the side with the other tumbler spring wells faces up. 6. Insert the tumbler springs (4) into the 4 spring wells. 7. The first tumbler closest to the head of the lock cylinder to be loaded will be the fourth key cut position. Install the remaining tumblers for key cut positions 6, 8 and 10. Press the tumblers in place until they are secure. 8. Check the correct loading of the tumblers by inserting the key into the cylinder. All of the tumblers should be flushed with the lock cylinder body. 9. Apply lubricant to the cylinder body and tumbler surfaces along with a small amount in the head of the cylinder using the supplied lubricant. 10. Install the retainer (5) into the spring wells in the head of the lock cylinder. 11. Snap the shutter (7) into the cylinder. 12. Assemble the cylinder into the case (3). 13. Align dimples of the cylinder cap (6) with the 4 recesses in the cap. Secure by pressing the cap into place with light hand pressure. 14. Assemble the rod clip (2) to the lever (1). 15. Assemble the lever (1) to the lock. Use driver unit (11) to retain the lever assembly. 16. Assemble the gasket to the lock. 17. Insert the key into the lock and function the lock to check for proper assembly and smooth operation. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Neutral Safety Switch: Recalls Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 826 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 827 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Neutral Safety Switch: All Technical Service Bulletins Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 833 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 834 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Procedures Steering Angle Sensor: Procedures Steering Angle Sensor Centering The external column mounted steering angle sensor does not require a centering often. Centering of the steering angle sensor might be required after certain service procedures are performed. Some of these procedures are as follows: * Electronic brake control module (EBCM) replacement * Steering angle sensor replacement * Steering gear replacement * Steering column replacement * Collision or other physical damage The external column mounted steering angle sensor centering procedure can be completed with a scan tool using the following steps: 1. Using the steering wheel, align the front wheels forward. 2. Apply the parking brake, or set the transmission in the P position. 3. Install the scan tool to the data link connector. 4. Ignition ON, engine OFF 5. Select Steering Wheel Angle Sensor Reset in the Steering Wheel Angle Sensor Module Configuration/Reset Functions list. 6. Follow the scan tool directions to complete the learn procedure. 7. Select Steering Wheel Angle Sensor Learn in the Steering Wheel Angle Sensor Module Configuration/Reset Functions list. 8. Follow the scan tool directions to complete the learn procedure. 9. Select Steering Wheel Angle Sensor Learn in the EBCM Configuration/Reset Functions list. 10. Follow the scan tool directions to complete the learn procedure. 11. Clear any DTCs that may be set. 12. If equipped with electric power steering (EPS), perform the Software Endstop Learning. Refer to Power Steering Control Module Calibration ( See: Relays and Modules/Relays and Modules - Steering and Suspension/Relays and Modules Steering/Steering Control Module/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Procedures > Page 842 Steering Angle Sensor: Removal and Replacement Steering Angle Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Procedures Steering Angle Sensor: Procedures Steering Angle Sensor Centering The external column mounted steering angle sensor does not require a centering often. Centering of the steering angle sensor might be required after certain service procedures are performed. Some of these procedures are as follows: * Electronic brake control module (EBCM) replacement * Steering angle sensor replacement * Steering gear replacement * Steering column replacement * Collision or other physical damage The external column mounted steering angle sensor centering procedure can be completed with a scan tool using the following steps: 1. Using the steering wheel, align the front wheels forward. 2. Apply the parking brake, or set the transmission in the P position. 3. Install the scan tool to the data link connector. 4. Ignition ON, engine OFF 5. Select Steering Wheel Angle Sensor Reset in the Steering Wheel Angle Sensor Module Configuration/Reset Functions list. 6. Follow the scan tool directions to complete the learn procedure. 7. Select Steering Wheel Angle Sensor Learn in the Steering Wheel Angle Sensor Module Configuration/Reset Functions list. 8. Follow the scan tool directions to complete the learn procedure. 9. Select Steering Wheel Angle Sensor Learn in the EBCM Configuration/Reset Functions list. 10. Follow the scan tool directions to complete the learn procedure. 11. Clear any DTCs that may be set. 12. If equipped with electric power steering (EPS), perform the Software Endstop Learning. Refer to Power Steering Control Module Calibration ( See: Relays and Modules/Relays and Modules - Steering and Suspension/Relays and Modules Steering/Steering Control Module/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Procedures > Page 849 Steering Angle Sensor: Removal and Replacement Steering Angle Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 855 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: If any of the following tire pressure sensor components are found to be damage, replace the damaged components. 4. Remove the tire pressure sensor indicator cap and deflate the tire. 5. Remove tire pressure sensor indicator nut (4). Note: When removing the tire pressure sensor, DO NOT re-use the seal, replace with new. 6. Remove the tire pressure sensor seal (3), the washer (2) and the tire pressure sensor (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 856 1. Clean the area around the mounting point for the tire pressure sensor. 2. Install the washer (2) and the seal (3) on the tire pressure sensor (1). 3. Install the tire pressure sensor (1) on the wheel. 4. Start the nut (4) by hand. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: When installing the tire pressure sensor and the nut, position the tire pressure sensor so that it is parallel to the inside wheel surface while torquing. 5. Install the nut (2) on the tire pressure sensor (1). Tighten the nut (2) to 7 Nm (62 lb in). 6. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). 7. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 857 and Repair). 8. Lower the vehicle. 9. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Service and Repair/Tire Pressure Indicator Sensor Learn). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair Transmission Position Switch/Sensor: Service and Repair Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Special Tools DT-41229 - Manual Shaft Pin Installer For equivalent regional tools, refer to Special Tools (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Tools and Equipment). Removal Procedure 1. Remove the control valve body. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 2. Remove the manual shaft detent lever hub pin (1) using a pry bar and pliers. 3. Remove and DISCARD the manual shift shaft pin (5). 4. Remove the manual shaft (2). 5. Disconnect the actuator rod (3) from the detent lever assembly. Do not remove the actuator rod from the transmission case. 6. Remove the manual shaft detent (with shift position switch) lever assembly (4). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Page 863 1. Connect the actuator rod (3) to the detent lever assembly. 2. Install the manual shaft detent (with shift position switch) lever assembly (4). 3. Install the manual shaft (2). 4. Install the manual shaft detent lever hub pin (1) to height of 7.9 mm (0.38 in) (b). Caution: Use J 41229 to install the manual shaft pin at the correct height in order to properly secure the manual shaft. If you install the pin too deep, the case bore may crack. 5. Install the NEW manual shift shaft pin (5) using DT-41229 - pin installer. Use a NEW pin to ensure proper engagement with the case. 6. Inspect pin installed height is within 7.2-8.2 mm (0.28-0.32 in) (a). 7. Install the control valve body. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 8. Perform the transmission adaptive values learn procedure. Refer to Transmission Adaptive Values Learn (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Transmission Speed Sensor: Locations Component Location 1 - Reaction Carrier Assembly 2 - Control Valve Body Assembly 3 - Input Carrier Assembly 4 Valve Channel Plate 5 - Output Carrier Assembly 6 - Park Gear 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Drive Link Assembly 9 - Drive Sprocket 10 - Torque Converter Assembly 11 - A/Trans Fluid Pump Assembly 12 - Differential Carrier Assembly 13 - Front Differential Ring Gear 14 - Driven Sprocket 15 - 1-2-3-4 Clutch Assembly 16 - Low and Reverse Clutch Assembly 17 - 2-6 Clutch Assembly 18 - 3-5 Reverse Clutch Assembly 19 - 4-5-6 Clutch Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 867 20 - A/Trans Input Speed Sensor Assembly 21 - Reaction Sun Gear Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Replacement Transmission Speed Sensor: Service and Repair Output Speed Sensor Replacement Output Speed Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Replacement > Page 870 Transmission Speed Sensor: Service and Repair Input Speed Sensor Replacement Input Speed Sensor Replacement Removal Procedure 1. Remove the control valve body. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 2. Remove the input speed sensor bolt (2) M6 x 23. 3. Unlock the 2 retaining tabs inside the transmission housing. 4. Remove the input speed sensor (3). 5. Remove the 3 input speed sensor seals (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Replacement > Page 871 1. Install the 3 input speed sensor seals (1). 2. Install the input speed sensor (3). 3. Verify that the retaining tabs are locked completely. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the input speed sensor bolt (2) M6 x 23 and tighten to 9 Nm (80 lb in). 5. Install the control valve body. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 6. Perform the transmission adaptive values learn procedure. Refer to Transmission Adaptive Values Learn (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations Clutch Pedal Position Sensor / Switch: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations > Page 876 Clutch Pedal Position Sensor / Switch: Diagrams Component Connector End Views B25B Clutch Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations > Page 877 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Position Sensor Replacement Removal Procedure 1. Disconnect the clutch pedal position sensor wiring harness plug. 2. Remove the clutch pedal position sensor bolt (2). 3. Remove the clutch pedal position sensor (1). Installation Procedure 1. Install the clutch pedal position sensor (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the clutch pedal position sensor bolt (2) and tighten to 3 Nm(27 lb in). 3. Connect the clutch pedal position sensor wiring harness plug. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations > Page 878 4. Learn clutch pedal position sensor, refer to Clutch Pedal Position Sensor Learn (See: Transmission and Drivetrain/Manual Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations Door Component Views Driver Door Components 1 - S79D Window Switch - Driver 2 - S52 Outside Rearview Mirror Switch 3 - A9A Outside Rearview Mirror - Driver 4 - P19G Speaker - Left Front Front Passenger Door Components Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 883 1 - A9B Outside Rearview Mirror - Passenger 2 - S79P Window Switch - Passenger 3 - M74P Window Motor - Passenger 4 - P19U Speaker - Right Front Left Rear Passenger Side Door Components Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 884 1 - B27LR Door Handle Switch - Left Rear 2 - S79LR Window Switch - Left Rear 3 - M74LR Window Motor - Left Right Rear Passenger Side Door Components Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 885 1 - S79RR Window Switch - Right Rear 2 - B27RR Door Handle Switch - Right Rear 3 - M74RR Window Motor - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 886 Power Window Switch: Diagrams Component Connector End Views S79D Window Switch - Driver (AEC) S79D Window Switch - Driver (AXG) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 887 S79LR Window Switch - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 888 S79P Window Switch - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 889 S79RR Window Switch - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 890 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Multifunction Switch Replacement Power Window Switch: Service and Repair Front Side Door Window and Multifunction Switch Replacement Front Side Door Window and Multifunction Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Multifunction Switch Replacement > Page 893 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement Rear Side Door Window Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Multifunction Switch Replacement > Page 894 Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Right Side Front Side Door Window Switch Replacement - Right Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Multifunction Switch Replacement > Page 895 Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Left Side Front Side Door Window Switch Replacement - Left Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Locations Rain Sensor: Locations Passenger Compartment/Roof Component Views Roof/Headliner Components 1 - B160 Windshield Temperature and Inside Moisture Sensor 2 - K84 Remote Function Receiver Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Locations > Page 900 Rain Sensor: Diagrams Component Connector End Views B160 Windshield Temperature and Inside Moisture Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Windshield Washer Switch: Diagrams Component Connector End Views S80 Window Wiper/Washer Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 904 Windshield Washer Switch: Service and Repair Windshield Wiper and Washer Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Wiper Switch: Diagrams Component Connector End Views S80 Window Wiper/Washer Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 908 Wiper Switch: Service and Repair Windshield Wiper and Washer Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 914 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 915 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 916 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 917 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 918 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 919 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 920 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications Alignment: Specifications Trim Height Specifications Trim Height Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications > Page 923 Alignment: Specifications Wheel Alignment Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber Description Alignment: Description and Operation Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber Description > Page 926 Alignment: Description and Operation Toe Description Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber Description > Page 927 Alignment: Description and Operation Thrust Angles Description Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. If the thrust angle is not set properly the vehicle may "dog track", the steering wheel may not be centered or it could be perceived as a bent axle. Thrust angle can be checked during a wheel alignment. Positive thrust angle means the thrust line is pointing to the right hand side (RHS) of the vehicle. Negative thrust angle means the thrust line is pointing to the left hand side (LHS) of the vehicle. If the thrust angle is out of specification, moving the axle to body relationship will change the thrust angle reading. If the vehicle is out in the Positive (+) direction-moving the RHS forward and/or LHS rearward will move the thrust angle towards zero degrees. If the vehicle is out in the Negative (-) direction-moving the RHS rearward and/or LHS forward will move the thrust angle towards zero degrees. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber Description > Page 928 Alignment: Description and Operation Lead/Pull Description Lead/Pull Description At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Note: Vehicles will tend to lead/pull in the direction of the road slope as part of normal operation. Lead/pull is usually caused by the following factors: * Road slope * Variability in tire construction * Wheel alignment (front cross caster and camber) * Unbalanced steering gear * Electronic power steering (EPS) steering position and torque sensors not calibrated correctly, if equipped Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber Description > Page 929 Alignment: Description and Operation Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Thrust Angles Description Thrust Angles Description Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber Description > Page 930 The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. If the thrust angle is not set properly the vehicle may "dog track", the steering wheel may not be centered or it could be perceived as a bent axle. Thrust angle can be checked during a wheel alignment. Positive thrust angle means the thrust line is pointing to the right hand side (RHS) of the vehicle. Negative thrust angle means the thrust line is pointing to the left hand side (LHS) of the vehicle. If the thrust angle is out of specification, moving the axle to body relationship will change the thrust angle reading. If the vehicle is out in the Positive (+) direction-moving the RHS forward and/or LHS rearward will move the thrust angle towards zero degrees. If the vehicle is out in the Negative (-) direction-moving the RHS rearward and/or LHS forward will move the thrust angle towards zero degrees. Lead/Pull Description Lead/Pull Description At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Note: Vehicles will tend to lead/pull in the direction of the road slope as part of normal operation. Lead/pull is usually caused by the following factors: * Road slope * Variability in tire construction * Wheel alignment (front cross caster and camber) * Unbalanced steering gear * Electronic power steering (EPS) steering position and torque sensors not calibrated correctly, if equipped Torque Steer Description Torque Steer Description Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber Description > Page 931 A vehicle pulls or leads in one direction during hard acceleration. A vehicle pulls or leads in the other direction during deceleration. The following factors may cause torque steer to be more apparent on a particular vehicle: * A slightly smaller diameter tire on the right front increases a right torque lead. Inspect the front tires for differences in the brand, the construction, or the size. If the tires appear to be similar, change the front tires from side-to-side and retest the vehicle. Tire and wheel assemblies have the most significant effect on torque steer correction. * A large difference in the right and left front tire pressure * Left-to-right differences in the front view axle angle may cause significant steering pull in a vehicle. The pull will be to the side with the most downward sloping axle from the differential to the wheels. Axles typically slope downward from the differential. The slope of the transaxle pan to level ground may be used as an indication of bias axle angles. The side with the higher transaxle pan (shown on the left side of the illustration) has the most downward sloping axle angle. Memory Steer Description Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 932 Alignment: Testing and Inspection Trim Height Inspection Trim Height Measurement Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause the vehicle to bottom out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: * Set the tire pressure to the specifications shown on the certification label. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Note: One U.S. gallon of gasoline weighs approximately 6.5 lbs. One liter of gasoline weighs approximately 0.78 kg. * Check the fuel level. Add additional weight if necessary to simulate a full tank. * Make sure the passenger and rear compartments are empty, except to the spare tire. * Make sure the vehicle is on a flat and level surface, such as an alignment rack. * Check that all the vehicle doors are securely closed. * Check that the vehicle hood and rear deck lid are securely closed. * Make sure the vehicle is free of ice, snow and mud accumulation. * Check for installed after market accessories or modifications that could affect trim height measurement: - Larger or smaller than production wheels and tires. - Lifting or lowering kits - Wheel opening flares or ground affects Measuring the P and R Dimension Measurement Definitions P Height: The vertical distance from the ground to the top of the wheel opening through the centerline of the front wheel. R Height: The vertical distance from the ground to the top of the wheel opening through the centerline of the rear wheel. Use the following procedures to measure the P and R dimensions: Note: * Measure from the center of the wheel well opening to the ground. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 933 * The left and right P and R height differences should be no more than 10 mm (0.39 in). 1. Push the front bumper down a minimum of 25 mm (1 in) , and release. Perform this step three times. 2. Measure and record the trim height per the "Measurement Definitions" above. 3. Lift the bumper up a minimum of 25 mm (1 in) , and release. Perform this step three times. 4. Measure and record the trim height per the "Measurement Definitions" above. 5. The true P height measurement is the average of the measurements taken in step 2 and 4. Refer to Trim Height Specifications (See: Specifications/Mechanical Specifications/Suspension/System Specifications/Trim Height Specifications). 6. Repeat the above steps at the rear of the vehicle for the R heights. 7. If the P and R heights are outside of the specifications, measure the Z and D heights. Measuring the Z Dimension Measurement Definitions The Z Height: The vertical distance from the cradle side rail bottom surface (2) accessed through hole in the engine shield to the center of the ball joint cup (1). Use the following procedures to measure the Z dimensions: Note: The left and right Z height differences should be no more than 10 mm (0.39 in). 1. Push the front bumper down a minimum of 25 mm (1 in). Perform this step three times. 2. Measure and record the trim height per the "Measurement Definitions" above. 3. Lift the front bumper a minimum of 25 mm (1 in). Perform this step three times. 4. Measure and record the trim height per the "Measurement Definitions" above. 5. The true Z height dimension is the average of the measurements taken in steps 2 and 4. Refer to Trim Height Specifications (See: Specifications/Mechanical Specifications/Suspension/System Specifications/Trim Height Specifications). 6. If these measurements are out of specifications, inspect for the following conditions: * Worn or damaged suspension components * Collision damage D Height Measurement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 934 Measurement Definitions The D Height: The vertical distance from the bottom surface of the body side rail (1) to the center of the lower shock attaching bolt head (2). Use the following procedure to check the D dimension: Note: The left and right D height difference should be no more than 10 mm (0.39 in). 1. Push the rear bumper down a minimum of 25 mm (1 in). Perform this step three times. 2. Measure and record the trim height per the "Measurement Definitions" above. 3. Lift the rear bumper up a minimum of 25 mm (1 in) , and release. Perform this step three times. 4. Measure and record the trim height per the "Measurement Definitions" above. 5. The true D height is the average of the measurements taken in steps 2 and 4. Refer to Trim Height Specifications (See: Specifications/Mechanical Specifications/Suspension/System Specifications/Trim Height Specifications). 6. If these measurements are out of specifications, inspect for the following conditions: * Worn or damaged suspension components * Collision damage Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment Measurement Alignment: Service and Repair Wheel Alignment Measurement Wheel Alignment Measurement Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Radial Tire Lead/Pull Correction) in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections in order to ensure correct alignment readings: * Inspect for visible damage to the suspension components and replace as necessary. * Inspect the tires for the proper inflation and irregular tire wear. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label) and Tire Diagnosis - Irregular or Premature Wear (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Tire Diagnosis - Irregular or Premature Wear). * Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications (See: Body and Frame/Testing and Inspection/Vibration Diagnosis and Correction/Specifications). * Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings Diagnosis (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Wheel Bearings Diagnosis). * Inspect the ball joints for looseness or wear. * Inspect the tie rod ends for looseness or wear. * Inspect the control arms and stabilizer shaft for looseness or wear. * Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications (See: Specifications/Mechanical Specifications/Steering/System Specifications). * Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Suspension Strut and Shock Absorber Testing - On Vehicle (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Suspension Strut and Shock Absorber Testing - On Vehicle). * Inspect the vehicle trim height. Refer to Trim Height Inspection (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection). * Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. * Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. Note: * Record the "Before" and "After" alignment measurements. * When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear toe adjustment first in order to obtain proper front alignment angles. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 937 Alignment: Service and Repair Front Camber Adjustment Front Camber Adjustment 1. Before performing any adjustment affecting the wheel alignment, refer to Wheel Alignment Measurement (See: Wheel Alignment Measurement). 2. Loosen both strut to knuckle nuts just enough to allow for movement. Note: If there is no adjustment for the camber, proceed to step 4. 3. Adjust the camber to specification by moving the top of the wheel in or out. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). 4. Remove the strut assembly from the vehicle. Refer to Strut Assembly Replacement (See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension/Strut Assembly Replacement). 5. Install the strut assembly in a soft jawed vise. Note: The inner hole should NOT be enlarged beyond that of the outer hole. 6. Using the appropriate tool, enlarge the inner hole (1) to match the outer hole (2). 7. Install the strut assembly. Refer to Strut Assembly Replacement (See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension/Strut Assembly Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 938 Note: If there is no adjustment for the camber, proceed to step 4. 8. Adjust the camber to specification by moving the top of the wheel in or out. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 939 Alignment: Service and Repair Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment 1. Ensure that the steering wheel is set in a straight ahead position. 2. Loosen the tie rod jam nut (1). 3. Adjust the toe to specification by turning the inner tie rod (2). Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the tie rod jam nut (1) to 60 Nm (44 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURE Fuel Pressure (Key ON, Engine OFF).................................................................................................. .............................................250-450 kPa (36-65 PSI) Should not decrease greater than........................................................................................................ .................................................34 kPa (5 PSI) in 1 min Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 944 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description When the ignition is turned ON, the engine control module (ECM) supplies power to the in-tank fuel pump, by energizing the fuel pump relay. The in-tank fuel pump remains ON as long as the engine is cranking or running and the ECM receives crankshaft reference pulses. If there are no reference pulses, the ECM turns the in-tank fuel pump OFF, 2 s after the ignition switch is turned ON or 2 s after the engine stops running. The electric fuel pump is incorporated into the modular fuel pump and sender assembly and is located inside the fuel tank. The fuel pump supplies fuel through a fuel filter, also located in the modular fuel pump and sender assembly, through the fuel feed pipes, to the fuel rail assembly. The fuel pump provides fuel at a pressure above the pressure needed by the fuel injectors. The fuel pressure regulator, located in the modular fuel pump and sender assembly, keeps the fuel available to the fuel injectors at a regulated pressure. When the fuel pressure rises above the pressure regulator calibration, the pressure is relieved, with excess fuel exhausted into the modular fuel pump and sender assembly reservoir. Reference Information Description and Operation Fuel System Description (See: Powertrain Management/Computers and Control Systems/Description and Operation/Fuel System Description) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Special Tools * CH 48027 - Digital Pressure Gauge * EN 37287 - Fuel Line Shut-Off Adapters For equivalent regional tools, refer to Special Tools (See: Powertrain Management/Computers and Control Systems/Tools and Equipment). Circuit/System Verification Note: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that an adequate amount of fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. 1. Ignition ON, command the KR23A Fuel Pump Relay ON with a scan tool. You should hear the G12 Fuel Pump turn ON and OFF. ‹› If the G12 Fuel Pump does not turn ON, refer to Fuel Pump Electrical Circuit Diagnosis (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Pump Electrical Circuit Diagnosis). 2. Ignition OFF, all accessories OFF, install the CH 48027 - Digital Pressure Gauge. 3. Ignition ON, command the KR23A Fuel Pump Relay ON with a scan tool. Verify the fuel pressure is between 250-450 kPa (36-65 PSI) and remains steady for 5 m. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 947 Circuit/System Testing Note: * The KR23A Fuel Pump Relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Do not start the engine. 1. Ignition ON, engine OFF, command the KR23A Fuel Pump Relay ON with a scan tool and observe the fuel pressure gauge while the G12 Fuel Pump is operating. Verify the fuel pressure is between 250-450 kPa (36-65 PSI). ‹› If the fuel pressure is greater than the specified range, replace the G12 Fuel Pump. ‹› If the fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all items test normal, replace the G12 Fuel Pump. * Restricted fuel feed pipe * Restricted or clogged strainer * Restricted or plugged fuel filter * Inspect the G12 Fuel Pump harness connectors and the ground circuits of the fuel pump for poor connections. Note: The fuel pressure may vary slightly when the G12 Fuel Pump stops operating. After the G12 Fuel Pump stops operating, the fuel pressure should stabilize and remain constant. 2. Verify the fuel pressure does not decrease greater than 34 kPa (5 PSI) in 1 min. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve fuel pressure. 2. Install the EN 37287 - Fuel Line Shut-Off Adapters between the fuel feed pipe and the fuel rail. 3. Open the valve on the EN 37287 - Fuel Line Shut-Off Adapters. 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the digital pressure gauge. 5. Close the valve on the EN 37287 - Fuel Line Shut-Off Adapters. 6. Verify the fuel pressure does not decrease greater than 34 kPa (5 PSI) in 1 minute. ‹› If the fuel pressure decreases more than 34 kPa (5 PSI) within the specified time, locate and replace the leaking fuel injector(s). ‹› If the fuel pressure does not decrease more than 34 kPa (5 PSI) within the specified time, replace the G12 Fuel Pump. 3. Relieve the fuel pressure to 69 kPa (10 PSI). Verify that the fuel pressure does not decrease more than 14 kPa (2 PSI) in 5 min. ‹› If the fuel pressure decreases more than the specified value, replace the G12 Fuel Pump. 4. Remove the EN 37287 - Fuel Line Shut-Off Adapters and CH 48027 - Digital Pressure Gauge. 5. Operate the vehicle within the conditions of the customers concern while monitoring fuel related parameters with a scan tool. The scan tool parameters should not indicate a lean condition. ‹› If the scan tool parameters indicate a lean condition, test for a restricted fuel feed pipe, restricted fuel filter, or poor connections at the harness connectors and ground circuits of the fuel pump. If all test normal, replace the fuel pump. 6. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls). Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 948 Fuel Pressure: Testing and Inspection Fuel Pressure Measurement Fuel Pressure Measurement Special Tools EN-34730-91 - Pressure Tester For equivalent regional tools, refer to Special Tools (See: Powertrain Management/Computers and Control Systems/Tools and Equipment) Warning Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Remove the protective cap from the test connection. 2. Attach the EN-34730-91 - tester (1) to the test connection. 3. Start the engine. * Bleed the pressure tester at idling speed. * Collect the exiting fuel in a suitable container. * Read the fuel pressure from the pressure gauge. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 4. Detach the pressure gauge EN-34730-91 - tester from the test connection. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > System Diagnosis Idle Speed: Testing and Inspection Throttle/Idle Learn The Idle Learn Procedure listed below must be performed whenever the following occurs: The crankshaft position variation learn procedure is also required when the following service procedures have been performed, regardless of whether or not DTC P0315 00 is set: * The throttle body assembly is replaced. * The throttle body is cleaned. * The engine control module (ECM) is replaced. * The idle air control valve is replaced. * Power disconnection (battery cable, ECM fuse, etc.) (Delphi ECM only) 1. Turn the ignition ON. 2. Turn the ignition OFF for 15 s. 3. Turn the ignition ON for 5 s. 4. Turn the ignition OFF for 15 s. 5. Start the engine in park/neutral. 6. Allow the engine to run until the engine coolant temperature is greater than 85°C (185°F). 7. Turn the A/C ON for 10 s, if equipped. 8. If the vehicle is equipped with an automatic transaxle, apply the parking brake. While pressing the brake pedal, place the transaxle in drive for 10 s. 9. Turn the A/C OFF for 10 s, if equipped. 10. If the vehicle is equipped with an automatic transaxle, while pressing the brake pedal, place the transaxle in park/neutral. 11. Turn the ignition OFF. The idle learn procedure is complete. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 957 Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Inlet Duct Replacement Air Cleaner Inlet Duct Replacement Removal Procedure 1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 2. Remove the intake air duct bolt (2). 3. Remove the intake air duct (1) Installation Procedure 1. Install the intake air duct (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 958 2. Install and tighten the intake air duct bolt (2). 3. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement (1.4L LUH and LUJ) Removal Procedure 1. Open hood. 2. Disconnect mass air flow sensor wiring harness plug (2) from mass air flow sensor (3). 3. Unclip mass air flow sensor wiring harness retainer clip from air cleaner housing (1). 4. Remove the air cleaner outlet duct clamp (3). 5. Remove the air cleaner outlet duct (2) from air cleaner housing (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 962 6. Remove the 5 air cleaner housing bolts (1). 7. Remove the air cleaner upper housing (2) from the air cleaner lower housing (4). 8. Remove the air cleaner element (3). Installation Procedure 1. Install the air cleaner element (3). 2. Install the air cleaner upper housing (2) to the air cleaner lower housing (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 5 air cleaner housing bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 963 4. Install the air cleaner outlet duct (2) to the air cleaner housing (1). 5. Install the air cleaner outlet duct clamp (3). 6. Clip in mass air flow sensor wiring harness retainer clip to air cleaner housing (1). 7. Connect the mass air flow sensor wiring harness plug 2) to the mass air flow sensor (3). 8. Close hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Special Tools EN-34730-91 - Pressure Tester For equivalent regional tools, refer to Special Tools (See: Powertrain Management/Computers and Control Systems/Tools and Equipment). Warning Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. Warning Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Remove the fuel injector rail cap (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 968 2. Relieve the fuel pressure. Use EN-34730-91 - pressure tester (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Ignition System Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Ignition System Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 975 Spark Plug: Application and ID Ignition System Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 976 Spark Plug: Testing and Inspection Spark Plug Inspection Spark Plug Usage 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications ( See: Application and ID) for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: * Spark plug fouling-Colder plug * Pre-ignition causing spark plug and/or engine damage-Hotter plug Spark Plug Inspection 1. Inspect the terminal post (1) for damage. * Inspect for a bent or broken terminal post (1). * Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: * Inspect the spark plug boot for damage. * Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 977 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. * Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications (See: Application and ID). An excessively wide electrode gap can prevent correct spark plug operation. * Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Application and ID). Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. * Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). * Inspect for a broken or worn side electrode (3). * Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. 5. A rattling sound indicates internal damage. 6. A loose center electrode (4) reduces the spark intensity. * Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. * Inspect for worn or missing platinum pads on the electrodes (3, 4) If equipped. * Inspect for excessive fouling. * Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Spark Plug Visual Inspection 1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: * Rich fuel mixtures * Leaking fuel injectors * Excessive fuel pressure * Restricted air filter element * Incorrect combustion * Reduced ignition system voltage output * Weak coils * Worn ignition wires * Incorrect spark plug gap * Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. * Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 978 Spark Plug: Service and Repair Spark Plug Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications All 4 cylinders must be tested to obtain valid test results. Record the readings. Maximum pressure differential............................................................................................................. .......................................................100 kPa (14.5 psi) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 982 Compression Check: Testing and Inspection Engine Compression Test Special Tools EN-48248 - Cylinder Compression Pressure Gauge For equivalent regional tools, refer to Special Tools (See: Engine, Cooling and Exhaust/Engine/Tools and Equipment). Removal Procedure 1. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement (1.4L LUH and LUJ) (See: Powertrain Management/Fuel Delivery and Air Induction/Throttle Body/Service and Repair/Removal and Replacement). 2. Remove the spark plugs. Refer to Spark Plug Replacement (See: Spark Plug/Service and Repair). 3. Remove the relay holder cover. 4. Remove the fuel pump relay. Note: The engine cranking time for the compression test should be less then 10 seconds and at 30 second intervals. 5. Crank the engine with the starter motor for 5 seconds to remove any foreign substances from the cylinders. 6. Prior to taking a compression reading, verify the cranking speed is greater than 300 RPM. If the cranking speed is below 300 RPM, repair the slow cranking speed condition before continuing with the compression test. 7. Install EN-48248 - gauge in the spark plug bore for the cylinder that is being checked. 8. Using the vehicle's starter motor, rotate or crank the engine for 4 compression strokes, puffs, for the cylinder being tested. 9. Observe the compression gauge and note the reading as the compression test is being performed. A normal cylinder reading will be indicated if compression builds up quickly and evenly to the specified level. An abnormal reading will be indicated if compression is low on the first compression stroke, starts increasing on the following compression strokes but does not reach the specified level. 10. Record the compression reading for the cylinder just tested. 11. Repeat steps for all remaining cylinders. All 4 cylinders must be tested to obtain valid test results. Record the readings. 12. Maximum pressure differential 100 kPa (14.5 psi). Installation Procedure 1. Install the fuel pump relay. 2. Install the relay holder cover. 3. Install the spark plugs. Refer to Spark Plug Replacement (See: Spark Plug/Service and Repair). 4. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement (1.4L LUH and LUJ) (See: Powertrain Management/Fuel Delivery and Air Induction/Throttle Body/Service and Repair/Removal and Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Drive Belt Routing Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 986 Drive Belt: Service Precautions Belt Dressing Caution Caution: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt: Testing and Inspection Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt Chirping, Squeal, and Whine Diagnosis Diagnostic Aids * A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It may be necessary to spray a small amount of water on the drive belts in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution. * If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. * A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or suspension component. Other items of the vehicle may also cause the noise. * The drive belts will not cause a whine noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belts one at a time and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 15. This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 16. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 17. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. 19. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 989 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 990 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 991 Drive Belt: Testing and Inspection Drive Belt Rumbling and Vibration Diagnosis Drive Belt Rumbling and Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused by, but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belts are installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belts the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspecting the drive belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation can be recognized at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt, nut, spacer, or washer was installed. 11. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known good water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 992 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 993 Drive Belt: Testing and Inspection Drive Belt Falls Off and Excessive Wear Diagnosis Drive Belt Falls Off and Excessive Wear Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears or sections of ribs missing. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut , spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. 13. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulley. 14. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 15. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 994 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 995 Drive Belt: Service and Repair Drive Belt Replacement Special Tools * EN-955-2 - Locking Pin * EN-48488 - Holding Wrench For equivalent regional tools, refer to Special Tools (See: Engine, Cooling and Exhaust/Engine/Tools and Equipment). Removal Procedure 1. Open the hood. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 3. Remove the right front compartment splash shield. Refer to Front Compartment Splash Shield Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Splash Shield Replacement). 4. Install EN-48488 - holding wrench (2) to the drive belt tensioner (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 996 5. Move the drive belt tensioner clockwise until the drive belt tensioner can be fixed with EN-955-2 locking pin (1). 6. Remove the EN-48488 - holding wrench. 7. Lower the vehicle. 8. Remove the right engine mount. Refer to Engine Mount Replacement - Right Side (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Removal and Replacement/Engine Mount Replacement - Right Side). 9. Remove the drive belt. Installation Procedure 1. Install the drive belt. 2. Install the right engine mount. Refer to Engine Mount Replacement Right Side (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Removal and Replacement/Engine Mount Replacement - Right Side). 3. Raise the vehicle. 4. Install the EN-48488 - holding wrench (2) to the drive belt tensioner (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 997 5. Move the drive belt tensioner clockwise until EN-955-2 - locking pin (1) can be removed. 6. Allow the tensioner to slide back slowly. 7. Remove the EN-48488 - holding wrench. 8. Install the front compartment splash shield right side. Refer to Front Compartment Splash Shield Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Splash Shield Replacement). 9. Lower the vehicle. 10. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 1004 Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Inlet Duct Replacement Air Cleaner Inlet Duct Replacement Removal Procedure 1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 2. Remove the intake air duct bolt (2). 3. Remove the intake air duct (1) Installation Procedure 1. Install the intake air duct (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 1005 2. Install and tighten the intake air duct bolt (2). 3. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement (1.4L LUH and LUJ) Removal Procedure 1. Open hood. 2. Disconnect mass air flow sensor wiring harness plug (2) from mass air flow sensor (3). 3. Unclip mass air flow sensor wiring harness retainer clip from air cleaner housing (1). 4. Remove the air cleaner outlet duct clamp (3). 5. Remove the air cleaner outlet duct (2) from air cleaner housing (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1009 6. Remove the 5 air cleaner housing bolts (1). 7. Remove the air cleaner upper housing (2) from the air cleaner lower housing (4). 8. Remove the air cleaner element (3). Installation Procedure 1. Install the air cleaner element (3). 2. Install the air cleaner upper housing (2) to the air cleaner lower housing (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 5 air cleaner housing bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1010 4. Install the air cleaner outlet duct (2) to the air cleaner housing (1). 5. Install the air cleaner outlet duct clamp (3). 6. Clip in mass air flow sensor wiring harness retainer clip to air cleaner housing (1). 7. Connect the mass air flow sensor wiring harness plug 2) to the mass air flow sensor (3). 8. Close hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair > Passenger Compartment Air Filter Replacement Cabin Air Filter: Service and Repair Passenger Compartment Air Filter Replacement Passenger Compartment Air Filter Replacement Removal Procedure 1. Remove instrument panel outer trim cover. Refer to Instrument Panel Outer Trim Cover Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Outer Trim Cover Replacement - Right Side). 2. Remove instrument panel compartment. Refer to Instrument Panel Compartment Replacement (See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Compartment Replacement). 3. Unclip 2 clips (1) and remove passenger compartment air filter (2). Installation Procedure 1. Install passenger compartment air filter (2) and clip in 2 clips (1). 2. Install instrument panel compartment. Refer to Instrument Panel Compartment Replacement (See: Body and Frame/Interior Moulding / Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair > Passenger Compartment Air Filter Replacement > Page 1015 Trim/Glove Compartment/Service and Repair/Instrument Panel Compartment Replacement). 3. Install instrument panel outer trim cover. Refer to Instrument Panel Outer Trim Cover Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Outer Trim Cover Replacement - Right Side). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair > Passenger Compartment Air Filter Replacement > Page 1016 Cabin Air Filter: Service and Repair Service Manual Procedures Passenger Compartment Air Filter Replacement Removal Procedure 1. Remove instrument panel outer trim cover. 2. Remove instrument panel compartment. 3. Unclip 2 clips (1) and remove passenger compartment air filter (2). Installation Procedure 1. Install passenger compartment air filter (2) and clip in 2 clips (1). 3. Install instrument panel outer trim cover. 2. Install instrument panel compartment. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Special Tools EN-34730-91 - Pressure Tester For equivalent regional tools, refer to Special Tools (See: Powertrain Management/Computers and Control Systems/Tools and Equipment). Warning Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. Warning Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Remove the fuel injector rail cap (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 1021 2. Relieve the fuel pressure. Use EN-34730-91 - pressure tester (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Open hood. 2. Place a drain pan below the vehicle. 3. Remove the engine oil filter cap (2) in compound with the engine oil filter cap seal ring (3) and the oil filter element (1). 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 5. Remove the oil pan drain plug and allow the oil to drain into the drain pan. Installation Procedure 1. Clean the oil pan drain plug thread in the oil pan. 2. Install a NEW seal ring to the oil pan drain plug. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the oil pan drain plug and tighten to 14 Nm (124 lb in). 4. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Page 1025 Note: Lubricate the NEW oil filter cap seal ring with engine oil. 5. Install the engine oil filter cap (2) in compound with a NEW engine oil filter cap seal ring (3) and a NEW oil filter element (1). Caution: Over torquing the oil filter cap may cause damage to the oil filter cap resulting in an oil leak. 6. Tighten the engine oil filter cap to 25 Nm (18 lb ft). Caution: Using engine oils of any viscosity other than those viscosities recommended could result in engine damage. Note: Do not overfill the engine with engine oil. 7. Fill in NEW engine oil. Refer to Engine Mechanical Specifications (See: Engine, Cooling and Exhaust/Engine/Specifications/Service Limits & General Specifications) to find the specified viscosity and volume. 8. Start the engine and allow it to run until the oil pressure control indicator goes off. 9. Inspect the engine oil level. 10. Close hood. 11. Reset the service interval indicator. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair Coolant Line/Hose: Service and Repair Engine Coolant Air Bleed Hose Replacement (1.4L LDD, LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement Heater Hose: Service and Repair Heater Inlet Hose Replacement Heater Inlet Hose Replacement (1.4L LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1034 Heater Hose: Service and Repair Heater Outlet Hose Replacement Heater Outlet Hose Replacement (1.4L LUJ) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). 2. Remove 2 heater outlet hose clamps (1). 3. Remove heater outlet hose (2). 4. Remove heater outlet hose clamps (2). 5. Remove heater outlet hose (3) from radiator surge tank (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1035 1. Install heater outlet hose (3) to radiator surge tank (1). 2. Install heater outlet hose clamps (2). 3. Install heater outlet hose (2). 4. Install 2 heater outlet hose clamps (1). 5. Refill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1036 Heater Hose: Service and Repair Heater Core Outlet Tube Replacement Heater Core Outlet Tube Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1037 Heater Hose: Service and Repair Heater Core Inlet Tube Replacement Heater Core Inlet Tube Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Air Conditioning Compressor and Condenser Hose Replacement Hose/Line HVAC: Service and Repair Air Conditioning Compressor and Condenser Hose Replacement Air Conditioning Compressor and Condenser Hose Replacement (1.4L LUJ) Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Heating and Air Conditioning/Service and Repair/Procedures/Refrigerant Recovery and Recharging). 2. Remove front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 3. Remove headlamp - right side. Refer to Headlamp Replacement (See: Lighting and Horns/Headlamp/Service and Repair). 4. Remove air conditioning compressor and condenser hose nut (1) from refrigerant hose (2). 5. Remove air conditioning compressor and condenser hose nut (3) from air conditioning condenser (4). 6. Remove and DISCARD the seals from the air conditioning compressor and condenser hose. 7. Remove air conditioning compressor and condenser hose bolt (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Air Conditioning Compressor and Condenser Hose Replacement > Page 1042 8. Remove air conditioning compressor and condenser hose. 9. Remove and DISCARD the air conditioning compressor and condenser hose seals (2). Installation Procedure 1. Install 4 NEW system seals to the air conditioning compressor and condenser hose. Refer to Air Conditioning System Seal Replacement (See: Heating and Air Conditioning/Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). 2. Install air conditioning compressor and condenser hose. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install air conditioning compressor and condenser hose bolt (1) tighten to 19 Nm (14 lb ft). 4. Install air conditioning compressor and condenser hose nut (3) to air conditioning condenser (4) and tighten to 19 Nm (14 lb ft). 5. Install air conditioning compressor and condenser hose nut (1) to air conditioning refrigerant hose (2) and tighten to 19 Nm (14 lb ft). 6. Install headlamp - right side. Refer to Headlamp Replacement (See: Lighting and Horns/Headlamp/Service and Repair). 7. Install front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 8. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging (See: Heating and Air Conditioning/Service and Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Air Conditioning Compressor and Condenser Hose Replacement > Page 1043 Repair/Procedures/Refrigerant Recovery and Recharging). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Air Conditioning Compressor and Condenser Hose Replacement > Page 1044 Hose/Line HVAC: Service and Repair Air Conditioning Evaporator Hose Assembly Replacement Air Conditioning Evaporator Hose Assembly Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Air Conditioning Compressor and Condenser Hose Replacement > Page 1045 Hose/Line HVAC: Service and Repair Suction Screen Installation Suction Screen Installation Special Tools GE-44551 - Suction Screen Kit Installation Procedure Note: Suction screens are intended to be installed in the suction hose after a major compressor failure. 1. Remove the A/C compressor and condenser hose from the A/C compressor. Refer to Air Conditioning Compressor and Condenser Hose Replacement (1.4L LUJ) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Removal and Replacement/Air Conditioning Compressor and Condenser Hose Replacement)Air Conditioning Compressor and Condenser Hose Replacement (1.8L LUW) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Removal and Replacement/Air Conditioning Compressor and Condenser Hose Replacement). 2. Using a caliper that reads to 3 decimal places, measure the ID of the manifold suction fitting. To determine the correct size screen for the application, refer to Compressor Suction Screen and Tool Selection Specifications (See: Heating and Air Conditioning/Specifications/Mechanical Specifications/Heating, Ventilation, and Air Conditioning/Compressor Suction Screen and Tool Selection Specifications). 3. Select and install the correct mandrel (1) on the threaded portion of the installation tool bolt: * The brass universal mandrel is for use on hose fittings with a smooth bore where the screen installs flush with the end of the fitting. * The 11.96 mm (0.471 in) mandrel is only for the 11.96 mm (0.471 in) screen in hose fittings with an internal hourglass shape where the screen installs at the recessed, reduced diameter point. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Air Conditioning Compressor and Condenser Hose Replacement > Page 1046 4. Install the 11.96 mm (0.471 in) screen in the middle of the reduced diameter point of the fitting. 5. Place the suction hose side of the manifold into the GE-44551-5 - installation tool fixture (3) so it is supported by the tools legs. Note: Correct placement of the GE-44551-5 - installation tool fixture is critical. 6. Lubricate the A/C suction screen with the applicable refrigerant oil. 7. Align the screen (2), basket first into the suction hose bore then hand tighten the bolt until contact is made between the hose, screen and tool. 8. Turn the bolt of the installation tool clockwise pressing the screen into the bore until the mandrel shoulder contacts the end of the hose fitting. 9. Unscrew the bolt and remove the installation tool from the manifold. Note: Clean the surface to be used for attaching the label. 10. Install the GE-44551-1 - Suction Screen Notification Label. 11. Install the A/C compressor and condenser hose to the A/C compressor. Refer to Air Conditioning Compressor and Condenser Hose Replacement (1.4L LUJ) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Removal and Replacement/Air Conditioning Compressor and Condenser Hose Replacement)Air Conditioning Compressor and Condenser Hose Replacement (1.8L LUW) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Removal and Replacement/Air Conditioning Compressor and Condenser Hose Replacement ). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Air Conditioning Compressor and Condenser Hose Replacement > Page 1047 Hose/Line HVAC: Service and Repair Suction Screen Replacement Suction Screen Replacement Special Tools GE-44551 - Suction Screen Kit Removal Procedure Note: Suction screens are intended to be installed in the suction hose after a major compressor failure. 1. Remove the A/C compressor and condenser hose from the A/C compressor. Refer to Air Conditioning Compressor and Condenser Hose Replacement (1.4L LUJ) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Removal and Replacement/Air Conditioning Compressor and Condenser Hose Replacement)Air Conditioning Compressor and Condenser Hose Replacement (1.8L LUW) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Removal and Replacement/Air Conditioning Compressor and Condenser Hose Replacement). 2. Using the GE-44551-9 - Universal Removal Tool , place the tip of the tool under the inside edge of the compression band of the suction screen and the cushioning fulcrum pad against the open end of the manifold fitting. Note: Do not damage the end of the hose or manifold. 3. Pry upward on the band and move the tool around the diameter of the screen as necessary to remove the screen. Installation Procedure 1. Using a caliper that reads to 3 decimal places, measure the ID of the manifold suction fitting. To determine the correct size screen for the application, refer to Compressor Suction Screen and Tool Selection Specifications (See: Heating and Air Conditioning/Specifications/Mechanical Specifications/Heating, Ventilation, and Air Conditioning/Compressor Suction Screen and Tool Selection Specifications). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Air Conditioning Compressor and Condenser Hose Replacement > Page 1048 2. Select and install the correct mandrel (1) on the threaded portion of the installation tool bolt: * The brass universal mandrel is for use on hose fittings with a smooth bore where the screen installs flush with the end of the fitting. * The 11.96 mm (0.471 in) mandrel is only for the 11.96 mm (0.471 in) screen in hose fittings with an internal hourglass shape where the screen installs at the recessed, reduced diameter point. * Install the 11.96 mm (0.471 in) screen in the middle of the reduced diameter point of the fitting. 3. Place the suction hose side of the manifold into the GE-44551-5 - installation tool fixture (3) so it is supported by the tools legs. Note: Correct placement of the GE-44551-5 - installation tool fixture is critical. 4. Lubricate the A/C suction screen with the applicable refrigerant oil. 5. Align the screen (2), basket first into the suction hose bore then hand tighten the bolt until contact is made between the hose, screen and tool. 6. Turn the bolt of the installation tool clockwise pressing the screen into the bore until the mandrel shoulder contacts the end of the hose fitting. 7. Unscrew the bolt and remove the installation tool from the manifold. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Air Conditioning Compressor and Condenser Hose Replacement > Page 1049 Note: Clean the surface to be used for attaching the label. 8. Install the GE-44551-1 - Suction Screen Notification Label. 9. Install the A/C compressor and condenser hose to the A/C compressor. Refer to Air Conditioning Compressor and Condenser Hose Replacement (1.4L LUJ) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Removal and Replacement/Air Conditioning Compressor and Condenser Hose Replacement)Air Conditioning Compressor and Condenser Hose Replacement (1.8L LUW) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Removal and Replacement/Air Conditioning Compressor and Condenser Hose Replacement ). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service Precautions Power Steering Line/Hose: Service Precautions Power Steering Hose Disconnected Caution Caution: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected. When disconnected, plug or cap all openings of components. Failure to do so could result in contamination or loss of power steering fluid and damage to the system. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement Radiator Hose: Service and Repair Radiator Inlet Hose Replacement Radiator Inlet Hose Replacement (LDD, LUH, and LUJ) (1.4L) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 1057 Radiator Hose: Service and Repair Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement (LDD, LUH, and LUJ) (1.4L) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Hydraulic Brake System: DOT 3 Hydraulic Brake Fluid (GM Part No. U.S. 88862806, in Canada 88862807). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System ................................................................................................................................... ................................................. 5.8 quarts (5.5 liters) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1066 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in the vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in the vehicle for five years or 240 000 km (150,000 miles), whichever occurs first. The following explains the cooling system and how to check and add coolant when it is low. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. If using this mixture, nothing else needs to be added. This mixture: Gives freezing protection down to -34°F (-37°C). Gives boiling protection up to 265°F (129°C). Protects against rust and corrosion. Will not damage aluminum parts. Helps keep the proper engine temperature. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. NOTICE: If extra inhibitors and/or additives are used in the vehicle's cooling system, the vehicle could be damaged. Use only the proper mixture of the engine coolant listed for the cooling system. Never dispose of engine coolant by putting it in the trash, pouring it on the ground, or into sewers, streams, or bodies of water. Have the coolant changed by an authorized service center, familiar with legal requirements regarding used coolant disposal. This will help protect the environment and your health. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Water Or Coolant Contamination Information Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Water Or Coolant Contamination Information > Page 1071 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Fluid Capacity Specifications (6T40/45/50) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1074 Fluid - A/T: Fluid Type Specifications Automatic Transmission DEXRON-VI Automatic Transmission Fluid. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1075 Fluid - A/T: Service Precautions Checking Hot Transmission Fluid through Drain Plug Hole Warning Warning The engine must be running when the transmission fluid fill plug is removed, or excessive fluid loss will occur. Transmission fluid may be hot. Since the actual fluid level is unknown, stand clear when removing the fill plug. Have a container ready to capture any lost fluid. Do not turn the engine off with the fill plug removed, as you can be injured by hot transmission fluid being expelled out of the oil fill opening. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1076 Fluid - A/T: Service and Repair Transmission Fluid Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the front compartment insulator. Refer to Front Compartment Insulator Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Insulator Replacement). 3. Remove the fluid level drain plug (1). 4. Drain transmission fluid into a suitable container. Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). 5. Install the fluid level drain plug (1) and tighten to 12 Nm (106 lb in). 6. Install the front compartment insulator. Refer to Front Compartment Insulator Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Insulator Replacement). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1077 1. Lower the vehicle. 2. Remove the battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). 3. Remove the transmission vent hose (2). 4. Remove the fluid filler cap (1). 5. Fill the transmission to the proper level with the correct fluid. Refer to Transmission Fluid Level and Condition Check (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Level and Condition Check) and Fluid Capacity Specifications (6T40/45/50) (See: Specifications/Capacity Specifications). 6. Install the fluid filler cap (1). 7. Install the transmission vent hose (2). 8. Install the battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Recalls for Fluid - M/T: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory Fluid - M/T: Recalls Campaign - Transmission Fluid Overfill From Factory SERVICE UPDATE Bulletin No.: 11008A Date: February 01, 2011 Subject: 11008A - Service Update for Inventory and Customer Vehicles - Transmission Fluid Overfill - Drain Excess Fluid - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Manual Transmission (MF3/MZ0) Supercede: The illustration for Step 9 in the Service Procedure has been revised to eliminate confusion on the amount of fluid to remove. Technicians are to remove 0.4L of transmission fluid after allowing the fluid to drain completely from the plug hole. Please discard all copies of bulletin 11008, issued January 2011. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to drain excess transmission fluid on certain 2011 model year Chevrolet Cruze vehicles with manual transmissions (MF3/MZ0). These vehicles may have received more than the required amount of transmission fluid, which could result in a hard shift and reduced fuel economy. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. Parts Information PN 55563377, plug, has been temporarily excluded from RIM. A sufficient number of plugs are being pre-shipped to involved dealers beginning January 21, 2011. The pre-shipped parts can be identified with control "Cruze-Recall", and will be shipped from Lansing, MI via Overnight Delivery. After you have received your preshipment of plugs, if you should still need additional parts, you can order them from General Motors Customer Care and Aftersales (GMCC&A;). Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Recalls for Fluid - M/T: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory > Page 1086 2. Remove the front compartment insulator. Refer to Front Compartment Insulator Replacement in SI. Oil Level Plug Shown on Manual Transmission Out of Vehicles Note There are three oil plugs on the manual transmission. There is a fill plug that is located on the top of the transmission below the battery tray. There is also a drain plug on the bottom of the transmission on the driver's side of the vehicle. The oil level plug (1) is located above the drain plug on the driver's side of the vehicle. Refer to the illustration. 3. Locate the oil level plug. 4. Place a basin below the transmission. 5. Place a shop towel or piece of plastic over the frame/front suspension as shown in the illustration. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Recalls for Fluid - M/T: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory > Page 1087 6. Remove the oil level plug. 7. Discard the oil level plug. 8. Allow the fluid to drain completely from the plug hole. Caution To preserve fluid quality and avoid harsh transmission shifts, after allowing the fluid to drain completely from the plug hole, remove 0.4L of transmission fluid. 9. Using a syringe and a 7.1mm (9/32 in) rubber hose, remove 0.4L of transmission fluid. 10. Clean all dirt and debris from the transmission oil level plug area. 11. Install a new oil level plug. Tighten Tighten the plug to 17 Nm (12.5 lb ft). 12. Remove the shop towel or plastic from the frame/front suspension. 13. Remove the transmission fluid from the vehicle frame, transmission, suspension and engine. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Recalls for Fluid - M/T: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory > Page 1088 14. Install the front compartment insulator. Refer to Front Compartment Insulator Replacement in SI. 15. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - M/T: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory Fluid - M/T: All Technical Service Bulletins Campaign - Transmission Fluid Overfill From Factory SERVICE UPDATE Bulletin No.: 11008A Date: February 01, 2011 Subject: 11008A - Service Update for Inventory and Customer Vehicles - Transmission Fluid Overfill - Drain Excess Fluid - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Manual Transmission (MF3/MZ0) Supercede: The illustration for Step 9 in the Service Procedure has been revised to eliminate confusion on the amount of fluid to remove. Technicians are to remove 0.4L of transmission fluid after allowing the fluid to drain completely from the plug hole. Please discard all copies of bulletin 11008, issued January 2011. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to drain excess transmission fluid on certain 2011 model year Chevrolet Cruze vehicles with manual transmissions (MF3/MZ0). These vehicles may have received more than the required amount of transmission fluid, which could result in a hard shift and reduced fuel economy. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. Parts Information PN 55563377, plug, has been temporarily excluded from RIM. A sufficient number of plugs are being pre-shipped to involved dealers beginning January 21, 2011. The pre-shipped parts can be identified with control "Cruze-Recall", and will be shipped from Lansing, MI via Overnight Delivery. After you have received your preshipment of plugs, if you should still need additional parts, you can order them from General Motors Customer Care and Aftersales (GMCC&A;). Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - M/T: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory > Page 1094 2. Remove the front compartment insulator. Refer to Front Compartment Insulator Replacement in SI. Oil Level Plug Shown on Manual Transmission Out of Vehicles Note There are three oil plugs on the manual transmission. There is a fill plug that is located on the top of the transmission below the battery tray. There is also a drain plug on the bottom of the transmission on the driver's side of the vehicle. The oil level plug (1) is located above the drain plug on the driver's side of the vehicle. Refer to the illustration. 3. Locate the oil level plug. 4. Place a basin below the transmission. 5. Place a shop towel or piece of plastic over the frame/front suspension as shown in the illustration. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - M/T: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory > Page 1095 6. Remove the oil level plug. 7. Discard the oil level plug. 8. Allow the fluid to drain completely from the plug hole. Caution To preserve fluid quality and avoid harsh transmission shifts, after allowing the fluid to drain completely from the plug hole, remove 0.4L of transmission fluid. 9. Using a syringe and a 7.1mm (9/32 in) rubber hose, remove 0.4L of transmission fluid. 10. Clean all dirt and debris from the transmission oil level plug area. 11. Install a new oil level plug. Tighten Tighten the plug to 17 Nm (12.5 lb ft). 12. Remove the shop towel or plastic from the frame/front suspension. 13. Remove the transmission fluid from the vehicle frame, transmission, suspension and engine. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - M/T: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory > Page 1096 14. Install the front compartment insulator. Refer to Front Compartment Insulator Replacement in SI. 15. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1101 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1102 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ ............................................. 4.25 quarts (4.0 liters) IMPORTANT: Oil filter should be changed at every oil change. NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1105 Engine Oil: Fluid Type Specifications Selecting the Right Engine Oil Selecting the right engine oil depends on both the proper oil specification and viscosity grade: Specification Use and ask for engine oils with the dexosTM certification mark. Oils meeting the requirements of the vehicle should have the dexos certification mark on the container. This certification mark indicates that the oil has been approved to the dexos specification. This vehicle was filled at the factory with dexos-approved engine oil. Notice: Use only engine oil that is approved to the dexos specification or an equivalent engine oil of the appropriate viscosity grade. Engine oils approved to the dexos specification will show the dexos symbol on the container. Failure to use the recommended engine oil or equivalent can result in engine damage not covered by the vehicle warranty. If you are unsure whether the oil is approved to the dexos specification, ask your service provider. Use of Substitute Engine Oils if dexos is unavailable: In the event that dexos-approved engine oil is not available at an oil change or for maintaining proper oil level, you may use substitute engine oil displaying the API Starburst symbol and of SAE 5W-30 viscosity grade. Use of oils that do not meet the dexos specification, however, may result in reduced performance under certain circumstances. Viscosity Grade SAE 5W-30 is the best viscosity grade for the vehicle. Do not use other viscosity oils such as SAE 10W-30, 10W-40, or 20W-50. Cold Temperature Operation: In an area of extreme cold, where the temperature falls below -29°C (-20°F), an SAE 0W-30 oil should be used. An oil of this viscosity grade will provide easier cold starting for the engine at extremely low temperatures. When selecting an oil of the appropriate viscosity grade, be sure to always select an oil that meets the required specification, dexos. "Specification" earlier in this section for more information. Engine Oil Additives/Engine Oil Flushes Do not add anything to the oil. The recommended oils with the dexos specification and displaying the dexos certification mark are all that is needed for good performance and engine protection. Engine oil system flushes are not recommended and could cause engine damage not covered by the vehicle warranty. What to Do with Used Oil Used engine oil contains certain elements that can be unhealthy for your skin and could even cause cancer. Do not let used oil stay on your skin for very long. Clean your skin and nails with soap and water, or a good hand cleaner. Wash or properly dispose of clothing or rags containing used engine oil. the manufacturer's warnings about the use and disposal of oil products. Used oil can be a threat to the environment. If you change your own oil, be sure to drain all the oil from the filter before disposal. Never dispose of oil by putting it in the trash or pouring it on the ground, into sewers, or into streams or bodies of water. Recycle it by taking it to a place that collects used oil. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1106 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Open hood. 2. Place a drain pan below the vehicle. 3. Remove the engine oil filter cap (2) in compound with the engine oil filter cap seal ring (3) and the oil filter element (1). 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 5. Remove the oil pan drain plug and allow the oil to drain into the drain pan. Installation Procedure 1. Clean the oil pan drain plug thread in the oil pan. 2. Install a NEW seal ring to the oil pan drain plug. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the oil pan drain plug and tighten to 14 Nm (124 lb in). 4. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1107 Note: Lubricate the NEW oil filter cap seal ring with engine oil. 5. Install the engine oil filter cap (2) in compound with a NEW engine oil filter cap seal ring (3) and a NEW oil filter element (1). Caution: Over torquing the oil filter cap may cause damage to the oil filter cap resulting in an oil leak. 6. Tighten the engine oil filter cap to 25 Nm (18 lb ft). Caution: Using engine oils of any viscosity other than those viscosities recommended could result in engine damage. Note: Do not overfill the engine with engine oil. 7. Fill in NEW engine oil. Refer to Engine Mechanical Specifications (See: Engine, Cooling and Exhaust/Engine/Specifications/Service Limits & General Specifications) to find the specified viscosity and volume. 8. Start the engine and allow it to run until the oil pressure control indicator goes off. 9. Inspect the engine oil level. 10. Close hood. 11. Reset the service interval indicator. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Page 1111 Power Steering Fluid: Service Precautions Air in the Power Steering System Caution Caution: If the power steering system has been serviced, an accurate fluid level reading cannot be obtained unless air is bled from the steering system. The air in the fluid may cause pump cavitation noise and may cause pump damage over a period of time. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant System Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1116 Refrigerant: Fluid Type Specifications Refrigerant System Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1117 Refrigerant: Service and Repair Refrigerant Recovery and Recharging Special Tools GE-45037 - A/C Oil Injector For equivalent regional tools, refer to Special Tools (See: Heating and Air Conditioning/Tools and Equipment/Heating, Ventilation, and Air Conditioning). Refrigerant Recovery and Recharging Warning To prevent personal injury, avoid breathing A/C Refrigerant and lubricant vapor or mist. Work in a well ventilated area. To remove refrigerant from the A/C System, use service equipment designed for recovery that is certified to meet the requirements of the appropriate SAE Standards. If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant, refrigerant recovery, and lubricant manufacturers. Warning For personal protection, goggles and lint-free gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If refrigerant comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Caution: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. Caution: To avoid system damage use only R-134a dedicated tools when servicing the A/C system. Caution: Do not mix refrigerant oils. Use of incorrect refrigerant oil will cause compressor failure. Caution: R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The AC filling device is a complete air conditioning service center for R-134a. The AC filling device recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The AC filling device automatically replenishes this vessel from an external source tank in order to maintain a constant volume of A/C refrigerant. The AC filling device has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the AC filling device will not recover the refrigerant from the A/C system. The AC filling device also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the AC filling device manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Specifications (See: Heating and Air Conditioning/Specifications/Capacity Specifications). A/C Refrigerant System Oil Charge Replenishing If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using GE-45037 - injector. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Specifications (See: Heating and Air Conditioning/Specifications/Capacity Specifications). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications Refrigerant Oil: Specifications Refrigerant System Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Antilock Brake System Automated Bleed Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Note: Before performing the ABS Automated Bleed Procedure, first perform a pressure bleed of the base brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Hydraulic Brake System Bleeding (Pressure)). The automated bleed procedure is recommended when one of the following conditions exist: * Base brake system bleeding does not achieve the desired pedal height or feel * Extreme loss of brake fluid has occurred * Air ingestion is suspected in the secondary circuits of the brake modulator assembly The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run the pump in order to purge any air from the secondary circuits. These circuits are normally closed off, and are only opened during system initialization at vehicle start up and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped in these circuits to flow out toward the brake corners. Performing the Automated Bleed Procedure Caution: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove all four tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Inspect the brake system for leaks and visual damage. Repair or replace components as needed. 4. Lower the vehicle. 5. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test). 6. Install a scan tool. 7. Turn the ignition ON, with the engine OFF. 8. With the scan tool, establish communications with the ABS system. Select Special Functions. Select Automated Bleed from the Special Functions menu. 9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 10. Following the directions given on the scan tool, pressure bleed the base brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Hydraulic Brake System Bleeding (Pressure)). 11. Follow the scan tool directions until the desired brake pedal height is achieved. 12. If the bleed procedure is aborted, a malfunction exists. Perform the following steps before resuming the bleed procedure: * If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) , and diagnose the appropriate DTC. * If the brake pedal feels spongy, perform the conventional brake bleed procedure again. Refer to Hydraulic Brake System Bleeding (Manual) ( See: Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Hydraulic Brake System Bleeding (Pressure)). 13. When the desired pedal height is achieved, press the brake pedal to inspect for firmness. 14. Lower the vehicle. 15. Remove the scan tool. 16. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 17. Inspect the brake fluid level. Refer to Master Cylinder Reservoir Filling (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). 18. Road test the vehicle while inspecting that the pedal remains high and firm. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed > Page 1125 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add GM approved brake fluid from a clean, sealed brake fluid container. Refer to Maintenance. See: If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Maintenance. See: 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed > Page 1126 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed > Page 1127 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) Special Tools * CH-29532-A - Brake Pressure Bleeder, or equivalent * CH-35589-A - Brake Pressure Bleeder Adapter For equivalent regional tools, refer to Special Tools (See: Brakes and Traction Control/Hydraulic System/Tools and Equipment). Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Note: The transmission must be in the PARK position, the power button in the OFF position, and the brakes not applied to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 1. Place the transmission in PARK. 2. Place the power button in the OFF position. 3. Remove the remote keyless entry (RKE) transmitter and close all of the vehicle doors. 4. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 5. With the power button OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 6. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 6.2-6.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 6.2-6.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 7. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 8. Install the CH-35589-A - Brake Pressure Bleeder Adapter to the brake master cylinder reservoir. 9. Check the brake fluid level in the CH-29532-A - Brake Pressure Bleeder, or equivalent. Add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 10. Connect the CH-29532-A - Brake Pressure Bleeder, or equivalent , to the CH-35589-A - Brake Pressure Bleeder Adapter. 11. Charge the CH-29532-A - Brake Pressure Bleeder, or equivalent , air tank to 175-205 kPa (25-30 psi). 12. Open the CH-29532-A - Brake Pressure Bleeder, or equivalent , fluid tank valve to allow pressurized brake fluid to enter the brake system. 13. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 14. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve. 16. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed > Page 1128 17. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 18. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 19. Install a transparent hose over the end of the bleeder valve, then repeat steps 16-17. 20. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 21. Install a transparent hose over the end of the bleeder valve, then repeat steps 16-17. 22. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 23. Install a transparent hose over the end of the bleeder valve, then repeat steps 16-17. 24. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 25. Close the CH-29532-A - Brake Pressure Bleeder, or equivalent , fluid tank valve, then disconnect the CH-29532-A - Brake Pressure Bleeder, or equivalent , from the CH-35589-A - Brake Pressure Bleeder Adapter. 26. Remove the CH-35589-A - Brake Pressure Bleeder Adapter from the brake master cylinder reservoir. 27. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 28. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 29. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to Antilock Brake System Automated Bleed (See: Antilock Brake System Automated Bleed). 30. Turn the power button ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 31. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed > Page 1129 Brake Bleeding: Service and Repair Hydraulic Brake System Flushing Hydraulic Brake System Flushing Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination: * Fluid separation, indicating two types of fluid are present; a substance other than the recommended brake fluid has been introduced into the brake hydraulic system: - Swirled appearance-oil-based substance - Layered appearance-silicone-based substance * Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system: - Cloudy appearance-moisture - Dark appearance/suspended particles in fluid-dirt, rust, corrosion, brake dust 2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination. 3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: 1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (Left Hand Drive) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement) * Front Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement) * Rear Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement) * Front Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement) * Rear Brake Caliper Replacement (with Dampener) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (with Dampener)) * Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake Pressure Modulator Valve Replacement) * Hydraulic Brake System Bleeding (Manual) (See: Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Hydraulic Brake System Bleeding (Pressure)) 2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (Left Hand Drive) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement); also perform the following: * Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Fluid Reservoir/Service and Repair). * Replace the brake master cylinder reservoir cap diaphragm. * Front Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement) * Rear Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement) * Front Brake Caliper Overhaul (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Overhaul)or Front Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed > Page 1130 * Rear Brake Caliper Replacement (with Dampener) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (with Dampener)) 4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The diaphragm may have allowed the moisture or particles to enter the hydraulic system. 5. Fill the brake master cylinder reservoir to the maximum-fill level with GM recommended brake fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Brakes and Traction Control/Specifications) for the recommended brake fluid. 6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) (See: Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Hydraulic Brake System Bleeding (Pressure)). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Restraint Systems/Air Bag Systems/Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 1134 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Restraint Systems/Air Bag Systems/Diagrams/Electrical Diagrams ) or Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block Fuse: Locations Engine Compartment Fuse Block Engine Compartment Fuse Block To remove the fuse block cover, squeeze the clips and swing it up. Notice: Spilling liquid on any electrical component on the vehicle may damage it. Always keep the covers on any electrical component. Engine Compartment Fuse Block The vehicle may not be equipped with all of the fuses, relays, and features shown. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 1140 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 1141 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 1142 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 1143 Fuse: Locations Instrument Panel Fuse Block Instrument Panel Fuse Block The instrument panel fuse block is in the driver side of the instrument panel. To access the Fuses: 1. Open the fuse block cover by pulling out at the top. 2. Remove the lower edge of the cover. 3. Remove the cover. To reinstall the cover, reverse the steps above. Instrument Panel Fuse Block Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 1144 The vehicle may not be equipped with all of the fuses, relays, and features shown. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 1145 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Fuse: Application and ID Fuse Block - Underhood Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1148 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1149 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1150 X50A Fuse Block - Underhood Bottom View X50A Fuse Block - Underhood Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1151 X50A Fuse Block - Underhood X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1152 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1153 X50A Fuse Block - Underhood X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1154 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1155 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1156 X50B Fuse Block - Underhood Auxiliary X8 X50B Fuse Block - Underhood Auxiliary X9 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1157 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1158 Fuse: Application and ID Fuse Block - Battery Electrical Center Identification Views X50D Fuse Block - Battery Auxiliary Top View X50D Fuse Block - Battery Auxiliary Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1159 X50D Fuse Block - Battery Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1160 X50D Fuse Block - Battery Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1161 X50D Fuse Block - Battery X3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1162 X50D Fuse Block - Battery X4 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1163 X50D Fuse Block - Battery X6 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1164 Fuse: Application and ID Fuse Block - Instrument Panel Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1165 X51A Fuse Block - Instrument Panel (Fuses) Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1166 X51A Fuse Block - Instrument Panel (Relays) Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1167 X51A Fuse Block - Instrument Panel Bottom View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 1168 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Harness Routing Views Fuse Block: Locations Harness Routing Views Harness Routing Views Forward Lamp Harness Routing 1 of 2 1 - X50A Fuse Block - Underhood 2 - X1 Fuse Block - Underhood X1 3 - X100 Body Harness and Body Front Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Harness Routing Views > Page 1173 Fuse Block: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 of 2 1 - X51A Fuse Block - Instrument Panel Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Harness Routing Views > Page 1174 Fuse Block: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left Side of the Engine Compartment Components 1 of 2 1 - X50D Fuse Block - Battery X5 2 - X50D Fuse Block - Battery X1 3 - X50D Fuse Block - Battery X6 4 - X50D Fuse Block - Battery X4 5 - X50D Fuse Block - Battery X3 6 - X50D Fuse Block Battery X2 7 - G122 Engine Compartment - Front Left 8 - X50D Fuse Block - Battery 9 - C1 Battery Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Fuse Block Replacement Fuse Block: Service and Repair Fuse Block Replacement Fuse Block Replacement Removal Procedure 1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection) 2. Unlock the retaining tabs on the battery fuse box cover, and open the cover (1). 3. Remove the positive battery cable to starter nut (2). 4. Remove the positive battery cable to starter (3) from the battery. 5. Remove the positive battery cable. Refer to Battery Positive Cable Replacement (See: Starting and Charging/Battery/Battery Cable/Positive/Service and Repair/Battery Positive Cable Replacement) 6. Remove 2 body wiring harness nuts (1) and body wiring harness. 7. Remove fuse block (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Fuse Block Replacement > Page 1177 Installation Procedure 1. Install fuse block. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 2. Install body wiring harness and 2 body wiring harness nuts. 4.7 Nm (42 lb in) 3. Install the positive battery cable. Refer to Battery Positive Cable Replacement (See: Starting and Charging/Battery/Battery Cable/Positive/Service and Repair/Battery Positive Cable Replacement) 4. Install the positive battery cable to starter (3). 5. Install the positive battery cable to starter nut (2). 9 Nm (80 lb in) 6. Close the battery fuse box cover (1) and lock the retaining tabs on the battery fuse box. 7. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Fuse Block Replacement > Page 1178 Fuse Block: Service and Repair Front Compartment Fuse Block Replacement Front Compartment Fuse Block Replacement Removal Procedure 1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Remove the front compartment fuse block cover. Refer to Front Compartment Fuse Block Cover Replacement (See: Front Compartment Fuse Block Cover Replacement). Note: Bolts (1) are encapsulated on the end of threads so that they can not be removed from the fuse block. 3. Remove the 3 front compartment fuse block bolt (1) and the front compartment fuse block wiring harness supply (2). 4. Unlock retaining tabs and remove the front compartment fuse block (3). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Fuse Block Replacement > Page 1179 1. Push down the 3 electrical connectors (3) before installation of the front compartment fuse block (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install front compartment fuse block wiring harness supply (1) and tighten to 12 Nm (106 lb in). 3. Install 3 front compartment fuse block bolt (1) and tighten to 6 Nm (53 lb in). 4. Install the front compartment fuse block cover. Refer to Front Compartment Fuse Block Cover Replacement (See: Front Compartment Fuse Block Cover Replacement). 5. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Fuse Block Replacement > Page 1180 Fuse Block: Service and Repair Front Compartment Fuse Block Housing Replacement Front Compartment Fuse Block Housing Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Fuse Block Replacement > Page 1181 Fuse Block: Service and Repair Front Compartment Fuse Block Cover Replacement Front Compartment Fuse Block Cover Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Battery Relay Box: Application and ID Fuse Block - Battery Electrical Center Identification Views X50D Fuse Block - Battery Auxiliary Top View X50D Fuse Block - Battery Auxiliary Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 1186 X50D Fuse Block - Battery Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 1187 X50D Fuse Block - Battery Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 1188 X50D Fuse Block - Battery X3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 1189 X50D Fuse Block - Battery X4 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 1190 X50D Fuse Block - Battery X6 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 1191 Relay Box: Application and ID Fuse Block - Underhood Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 1192 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 1193 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 1194 X50A Fuse Block - Underhood Bottom View X50A Fuse Block - Underhood Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 1195 X50A Fuse Block - Underhood X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 1196 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 1197 X50A Fuse Block - Underhood X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 1198 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 1199 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 1200 X50B Fuse Block - Underhood Auxiliary X8 X50B Fuse Block - Underhood Auxiliary X9 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 1201 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 1202 Relay Box: Application and ID Fuse Block - Instrument Panel Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 1203 X51A Fuse Block - Instrument Panel (Fuses) Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 1204 X51A Fuse Block - Instrument Panel (Relays) Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 1205 X51A Fuse Block - Instrument Panel Bottom View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 1206 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1212 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1213 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1214 Customer TPMS Information Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1215 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1216 Frequently Asked Questions Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module (ECM) turns the MIL ON by grounding the MIL control circuit. Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams/Powertrain Management/System Diagram) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) DTC Type Reference Powertrain Diagnostic Trouble Code (DTC) Type Definitions (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Powertrain Diagnostic Trouble Code (DTC) Type Definitions) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Circuit/System Verification 1. Ignition ON, observe the DTC information with a scan tool. Verify that DTCs U0073 00, U0100 00, or U0155 00 are not set. ‹› If any of the DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle). 2. Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool. Circuit/System Testing Ignition ON, verify that the P16 Instrument Cluster warning indicators are illuminated. If the P16 Instrument Cluster warning indicators are not illuminated, test the P16 Instrument Cluster ignition circuit terminal 31 for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the P16 Instrument Cluster. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Page 1220 * Instrument Cluster Replacement (See: Instrument Panel, Gauges and Warning Indicators/Compass/Service and Repair) * Control Module References (See: Testing and Inspection/Programming and Relearning)for ECM replacement, setup, and programming Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair Engine Oil LIfe System When to Change Engine Oil This vehicle has a computer system that indicates when to change the engine oil and filter. This is based on engine revolutions and engine temperature, and not on mileage. Based on driving conditions, the mileage at which an oil change is indicated can vary considerably. For the oil life system to work properly, the system must be reset every time the oil is changed. When the system has calculated that oil life has been diminished, it indicates that an oil change is necessary. A CHANGE ENGINE OIL SOON DIC message or Code 82 DIC message comes on. Engine Oil Messages. Change the oil as soon as possible within the next 1 000 km (600 mi). It is possible that, if driving under the best conditions, the oil life system might indicate that an oil change is not necessary for up to a year. The engine oil and filter must be changed at least once a year and, at this time, the system must be reset. It is also important to check the oil regularly over the course of an oil drain interval and keep it at the proper level. If the system is ever reset accidentally, the oil must be changed at 5 000 km (3,000 mi) since the last oil change. Remember to reset the oil life system whenever the oil is changed. How to Reset the Engine Oil Life System Reset the system whenever the engine oil is changed so that the system can calculate the next engine oil change. To reset the system: 1. Using the DIC MENU button and thumbwheel, scroll until you reach REMAINING OIL LIFE on the DIC (oil can symbol with % sign for Canada). 2. Press the SET button to reset the oil life at 100%. When prompted, use the thumbwheel to highlight YES or NO. Press the SET/CLEAR button to confirm. Be careful not to reset the oil life display accidentally at any time other than after the oil is changed. It cannot be reset accurately. If the CHANGE ENGINE OIL SOON DIC message or Code 82 DIC message comes back on when the vehicle is started, the engine oil life system has not reset. Repeat the procedure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Note: The use of a LOW PROFILE LIFT ARMS SYSTEM may be required to avoid unwanted contact with the vehicle's body and structure depending on lifting equipment used. Refer to the manufacture's recommendation for their applications of low profile lift arms system for their lifting equipment. Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Danger: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle contents. Vehicle Lifting - Frame Contact Lift Front Lift Pads When lifting the vehicle with a frame-contact lift, place the front lift pads on the rocker outer panel weld flange, as shown Rear Lift Pads Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 1228 When lifting the vehicle with a frame-contact lift, place the rear lift pads on the rocker outer panel weld flange, as shown. Vehicle Jacking Caution: When you are jacking the vehicle at the front locations, be certain that the jack or the jack lift pad does not contact the front fascia, front fascia air dam, or the front fenders. If such contact occurs, vehicle damage may result. When jacking at selected front locations additional clearance may be required for the jacking points. Note: When you are lifting a vehicle with a service jack, block the wheels at the opposite end from which you are lifting. Use jack stands to provide additional support. Front of Vehicle When using a service jack under the front of the vehicle use one of the following locations: Place the service jack pad in the same location as shown for the front lift pads. Rear of Vehicle Note: Place jackstands ONLY under strong and stable vehicle structures. Place the service jack pad in the same location as shown for the rear lift pads. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 1239 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any of the following tire pressure sensor components are found to be damage, replace the damaged components. 4. Remove the tire pressure sensor indicator cap and deflate the tire. 5. Remove tire pressure sensor indicator nut (4). Note: When removing the tire pressure sensor, DO NOT re-use the seal, replace with new. 6. Remove the tire pressure sensor seal (3), the washer (2) and the tire pressure sensor (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 1240 1. Clean the area around the mounting point for the tire pressure sensor. 2. Install the washer (2) and the seal (3) on the tire pressure sensor (1). 3. Install the tire pressure sensor (1) on the wheel. 4. Start the nut (4) by hand. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: When installing the tire pressure sensor and the nut, position the tire pressure sensor so that it is parallel to the inside wheel surface while torquing. 5. Install the nut (2) on the tire pressure sensor (1). Tighten the nut (2) to 7 Nm (62 lb in). 6. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 7. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 8. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 1241 9. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Tire Monitoring System/Service and Repair/Tire Pressure Indicator Sensor Learn). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1247 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1248 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1249 Customer TPMS Information Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1250 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1251 Frequently Asked Questions Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 1260 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any of the following tire pressure sensor components are found to be damage, replace the damaged components. 4. Remove the tire pressure sensor indicator cap and deflate the tire. 5. Remove tire pressure sensor indicator nut (4). Note: When removing the tire pressure sensor, DO NOT re-use the seal, replace with new. 6. Remove the tire pressure sensor seal (3), the washer (2) and the tire pressure sensor (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 1261 1. Clean the area around the mounting point for the tire pressure sensor. 2. Install the washer (2) and the seal (3) on the tire pressure sensor (1). 3. Install the tire pressure sensor (1) on the wheel. 4. Start the nut (4) by hand. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: When installing the tire pressure sensor and the nut, position the tire pressure sensor so that it is parallel to the inside wheel surface while torquing. 5. Install the nut (2) on the tire pressure sensor (1). Tighten the nut (2) to 7 Nm (62 lb in). 6. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 7. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 8. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 1262 9. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Service and Repair/Tire Pressure Indicator Sensor Learn). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips Tires: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1267 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1268 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1269 Customer TPMS Information Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1270 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1271 Frequently Asked Questions Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1272 Tires: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1273 Tires: Technical Service Bulletins Wheels/Tires - Use of Nitrogen Gas in Tires INFORMATION Bulletin No.: 05-03-10-020C Date: April 27, 2010 Subject: Use of Nitrogen Gas in Tires Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-03-10-020B (Section 03 - Suspension). GM's Position on the Use of Nitrogen Gas in Tires General Motors does not oppose the use of purified nitrogen as an inflation gas for tires. We expect the theoretical benefits to be reduced in practical use due to the lack of an existing infrastructure to continuously facilitate inflating tires with nearly pure nitrogen. Even occasional inflation with compressed atmospheric air will negate many of the theoretical benefits. Given those theoretical benefits, practical limitations, and the robust design of GM original equipment TPC tires, the realized benefits to our customer of inflating their tires with purified nitrogen are expected to be minimal. The Promise of Nitrogen: Under Controlled Conditions Recently, nitrogen gas (for use in inflating tires) has become available to the general consumer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. The following benefits under controlled conditions are attributed to nitrogen gas and its unique properties: - A reduction in the expected loss of Tire Pressure over time. - A reduction in the variance of Tire Pressures with temperature changes due to reduction of water vapor concentration. - A reduction of long term rubber degradation due to a decrease in oxygen concentrations. Important These are obtainable performance improvements when relatively pure nitrogen gas is used to inflate tires under controlled conditions. The Promise of Nitrogen: Real World Use Nitrogen inflation can provide some benefit by reducing gas migration (pressure loss) at the molecular level through the tire structure. NHTSA (National Highway Traffic Safety Administration) has stated that the inflation pressure loss of tires can be up to 5% a month. Nitrogen molecules are larger than oxygen molecules and, therefore, are less prone to "seeping" through the tire casing. The actual obtainable benefits of nitrogen vary, based on the physical construction and the materials used in the manufacturing of the tire being inflated. Another potential benefit of nitrogen is the reduced oxidation of tire components. Research has demonstrated that oxygen consumed in the oxidation process of the tire primarily comes from the inflation media. Therefore, it is reasonable to assume that oxidation of tire components can be reduced if the tire is inflated with pure nitrogen. However, only very small amounts of oxygen are required to begin the normal oxidation process. Even slight contamination of the tire inflation gas with compressed atmospheric air during normal inflation pressure maintenance, may negate the benefits of using nitrogen. GM Tire Quality, Technology and Focus of Importance Since 1972, General Motors has designed tires under the TPC (Tire Performance Criteria) specification system, which includes specific requirements that ensure robust tire performance under normal usage. General Motors works with tire suppliers to design and manufacture original equipment tires for GM vehicles. The GM TPC addresses required performance with respect to both inflation pressure retention, and endurance properties for original equipment tires. The inflation pressure retention requirements address availability of oxygen and oxidation concerns, while endurance requirements ensure the mechanical structure of the tire has sufficient strength. This combination has provided our customers with tires that maintain their structural integrity throughout their useful treadlife under normal operating conditions. Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Maintaining the correct inflation pressure allows the tire to perform as intended by the vehicle manufacturer in many areas, including comfort, fuel economy, stopping distance, cornering, traction, treadwear, and noise. Since the load carrying capability of a tire is related to inflation pressure, proper inflation pressure maintenance is necessary for the tire to support the load imposed by the vehicle without excessive structural Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1274 degradation. Important Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1275 Tires: Technical Service Bulletins Tires/Wheels - Tire Puncture Repair Procedures INFORMATION Bulletin No.: 04-03-10-001F Date: April 27, 2010 Subject: Tire Puncture Repair Procedures For All Cars and Light Duty Trucks Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-001E (Section 03 - Suspension). This bulletin covers puncture repair procedures for passenger car and light duty truck radial tires in the tread area only. The tire manufacturer must be contacted for its individual repair policy and whether or not the speed rating is retained after repair. Caution - Tire changing can be dangerous and should be done by trained professionals using proper tools and procedures. Always read and understand any manufacturer's warnings contained in their customers literature or molded into the tire sidewall. - Serious eye and ear injury may result from not wearing adequate eye and ear protection while repairing tires. - NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads. Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. - NEVER stand, lean or reach over the assembly during inflation. Repairable area on a radial tire. Important - NEVER repair tires worn to the tread indicators 1.59 mm (2/32") remaining depth). - NEVER repair tires with a tread puncture larger than 6.35 mm (1/4"). - NEVER substitute an inner tube for a permissible or non-permissible repair. - NEVER perform an outside-in tire repair (plug only, on the wheel). - Every tire must be removed from the wheel for proper inspection and repair. - Regardless of the type of repair used, the repair must seal the inner liner and fill the injury. - Consult with repair material supplier/manufacturer for repair unit application procedures and repair tools/repair material recommendations. Three basic steps for tire puncture repair: 1. Remove the tire from the wheel for inspection and repair. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1276 2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent air loss. External Inspection 1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak by using a water and soap solution. Mark the injured area and totally deflate the tire by removing the valve core. 2. Demount the tire from the wheel and place the tire on a well-lighted spreader. Internal Inspection 1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4. Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5. Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4") should not be repaired. Cleaning 1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a scraper. This step serves to remove dirt and mold lubricants to insure proper adhesion and non-contamination of the buffing tool. 2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow guidelines for handling and disposal. Clean the Injury Channel Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1277 1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to prevent damage to the repair unit. 3. Consult your repair material supplier for recommended reaming tool(s). Fill the Injury 1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent moisture from entering the tire fabric and steel wires. 2. (For combination repair/plug units skip this step.) Cement the injured channel and fill the injury from the inside of the tire with the repair plug per repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just above the inside tire surface. 3. Consult your repair material supplier for proper repair material selection. Repair Unit Selection Important Do not install the repair unit in this step. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1278 1. Center the repair unit over the injury as a reference and outline an area larger than the unit so that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit selection. Buffing 1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and evenly with a low speed buffing tool using a fine wire brush or gritted rasp. 2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult your repair material supplier for a proper buffing tool. Cementing Apply chemical cement according to the repair material manufacturer's procedures. Repair Unit Application Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1279 1. The tire must be in the relaxed position when the repair unit is installed (Do not spread the beads excessively). Two-Piece Plug and Repair Units 1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over the injury and stitch down thoroughly with the stitching tool, working from the center out. 3. Being careful not to stretch the plug material, cut the plug flush with the outer tread. Combination Repair/Plug Units 1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2. Follow the repair material manufacturer's recommendations for further installation instructions. 2. Consult your repair material supplier for the proper stitching tool. Safety Cage Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 1280 Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. Final Inspection 1. After remounting and inflating the tire, check both beads, the repair and the valve with a water and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel Assembly Balancing - OFF Vehicle. For additional tire puncture repair information, contact: Rubber Manufacturers Association (RMA) Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tread Wear Indicators Description Tires: Description and Operation Tread Wear Indicators Description Tread Wear Indicators Description The original equipment tires have tread wear indicators that show when you should replace the tires. The location of these indicators are at 60 degree intervals around the outer diameter of the tire. The indicators appear as a 6 mm (0.25 in) wide band when the tire tread depth becomes 1.6 mm (2/32 in). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tread Wear Indicators Description > Page 1283 Tires: Description and Operation Tire Inflation Description Tire Inflation Description This vehicle has been engineered to operate up to the stated load capacity with wheel and tire assemblies of the type, size, construction, and configuration as originally installed. Maintenance of the tire inflation pressures is critical to the continued satisfactory performance, handling, and operating economy of the vehicle. Operation with incorrectly or improperly inflated tires can adversely affect vehicle performance and may contribute to the following: * Reduced fuel economy * Tire overloading * Shortened tire life * Excessive tire wear * Uneven tire wear * Vehicle handling concerns Inspect the tire pressures when the vehicle has not been driven for at least 3 hours or not more than 1.6 km (1 mi) and when the tires are cool to the touch. Tire inflation pressures should be inspected monthly and before an extended trip and adjusted to meet the specifications listed for the particular vehicle. Replace any missing or damaged tire valve stem extensions and/or caps to prevent the intrusion of water and contaminates. One pound per square inch (psi) equals 6.9 kilopascals (kPa). The following table illustrates the conversion of kilopascals to pounds per square inch: For the correct inflation pressures refer to the vehicle's Tire Placard. Tires inflated to a higher than recommended pressure can contribute to the following conditions: * A hard ride * Tire bruising * Rapid tread wear at the center of the tire Tires inflated to a lower than recommended pressure can contribute to the following conditions: * Tire squeal on turns * Hard steering * Rapid and/or uneven wear on the outer edges of the tread * Tire rim bruises and tire rim rupture * Tire cord breakage * High tire temperatures * Sluggish vehicle handling * Higher fuel consumption Unequal pressure on the same axle can cause the following conditions: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tread Wear Indicators Description > Page 1284 * Uneven braking action * Steering lead * Imprecise vehicle handling Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tread Wear Indicators Description > Page 1285 Tires: Description and Operation P-Metric Sized Tires Description P-Metric Sized Tires Description The tire sidewall has a coded marking system, which provides information about the tire. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tread Wear Indicators Description > Page 1286 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures Tires: Procedures Tire Repair Warning * Tire changing can be dangerous and should be done by trained professionals using proper tools and procedures. Always read and understand any manufacturer's warnings contained in their customers literature or molded into the tire sidewall. * Serious eye and ear injury may result from not wearing adequate eye and ear protection while repairing tires. * NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads. * NEVER stand, lean or reach over the assembly during inflation. Note: Repairable area on a radial tire. * NEVER repair tires worn to the tread indicators 1.59 mm (2/32 in) remaining depth. * NEVER repair tires with a tread puncture larger than 6.35 mm (1/4 in). * NEVER substitute an inner tube for a permissible or non-permissible repair. * NEVER perform an outside-in tire repair (plug only, on the wheel). * Every tire must be removed from the wheel for proper inspection and repair. * Regardless of the type of repair used, the repair must seal the inner liner and fill the injury. * Consult with repair material supplier/manufacturer for repair unit application procedures and repair tools/repair material recommendations. Three basic steps for tire puncture repair: 1. Remove the tire from the wheel for inspection and repair. 2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent air loss. External Inspection 1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak by using a water and soap solution. Mark the injured area and totally deflate the tire by removing the valve core. 2. Demount the tire from the wheel and place the tire on a well-lighted spreader. Internal Inspection Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 1289 1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4. Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5. Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4 in) should not be repaired. Cleaning 1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a scraper. This step serves to remove dirt and mold lubricants to insure proper adhesion and non-contamination of the buffing tool. 2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow guidelines for handling and disposal. Clean the Injury Channel Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 1290 1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to prevent damage to the repair unit. 3. Consult your repair material supplier for recommended reaming tool(s). Fill the Injury 1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent moisture from entering the tire fabric and steel wires. 2. For combination repair/plug units skip this step. Cement the injured channel and fill the injury from the inside of the tire with the repair plug per repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just above the inside tire surface. 3. Consult your repair material supplier for proper repair material selection. Repair Unit Selection Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 1291 Note: Do not install the repair unit in this step. 1. Center the repair unit over the injury as a reference and outline an area larger than the unit so that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit selection. Buffing 1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and evenly with a low speed buffing tool using a fine wire brush or gritted rasp. 2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult your repair material supplier for a proper buffing tool. Cementing Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 1292 Apply chemical cement according to the repair material manufacturer's procedures. Repair Unit Application The tire must be in the relaxed position when the repair unit is installed. Do not spread the beads excessively. Two-Piece Plug and Repair Units 1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over the injury and stitch down thoroughly with the stitching tool, working from the center out. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 1293 3. Being careful not to stretch the plug material, cut the plug flush with the outer tread. Combination Repair/Plug Units 1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2. Follow the repair material manufacturer's recommendations for further installation instructions. Consult your repair material supplier for the proper stitching tool. Safety Cage Some run flat tires may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. Final Inspection Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 1294 1. After remounting and inflating the tire, check both beads, the repair and the valve with a water and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off Vehicle (See: Body and Frame/Testing and Inspection/Vibration Diagnosis and Correction/Repair Instructions/Tire and Wheel Assembly Balancing - Off Vehicle). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 1295 Tires: Removal and Replacement Tire Dismounting and Mounting Caution: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. Caution: Damage to either the tire bead or the wheel mounting holes can result from the use of improper wheel attachment or tire mounting procedures. It takes up to 70 seconds for all of the air to completely exhaust from a large tire. Failure to follow the proper procedures could cause the tire changer to put enough force on the tire to bend the wheel at the mounting surface. Such damage may result in vibration and/or shimmy, and under severe usage lead to wheel cracking. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Note: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel, position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Caution: Failure to position valve stem in proper position while dismounting and mounting the tire may result in the TPM sensor to become damaged. 5. Position the wheel and tire so the valve stem is at the 7 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 1296 6. Position the wheel and tire so the valve stem is again at the 7 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM, replace the tire pressure sensor. Refer to Tire Pressure Indicator Sensor Replacement (See: Sensors and Switches - Wheels and Tires/Tire Pressure Sensor/Service and Repair). 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Caution: When mounting the tires, use an approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A silicon base compound can cause the tire to slip on the rim. A corrosive type compound can cause tire or rim deterioration. 9. Apply mounting lubricant to the tire bead and the wheel rim. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications/Suspension). 10. Position the rim so the valve stem (1) is at the 7 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 1297 11. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. Ensure that the valve stem (1) is at the 7 o'clock position. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem (1) is at the 7 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 1298 13. Use the tire changer in order to install the tire to the wheel. Warning To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause serious personal injury. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1307 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1308 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1309 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 1314 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1319 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1320 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1321 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1327 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1328 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1329 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 1334 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1339 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1340 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1341 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 1346 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1351 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1352 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1353 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1359 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1360 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1361 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1366 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1367 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1368 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1369 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1370 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1371 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 1376 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1382 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1383 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1384 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1389 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1390 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1391 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1392 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1393 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1394 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 1399 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1400 Wheels: Description and Operation Replacement Wheels Description Replace the wheel if any of the following conditions exist: * The wheel exhibits excessive runout. * The wheel is bent. * The wheel is cracked. * The wheel is severely rusted. * The wheel is severely corroded. Note: Air leaks caused by porosity on aluminum wheels are repairable. * The wheel leaks air. Warning If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s), install only new GM original equipment parts. Installation of used parts or non-GM original equipment parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and loss of vehicle control resulting in personal injury. Caution: The use of non-GM original equipment wheels may cause: * Damage to the wheel bearing, the wheel fasteners and the wheel * Tire damage caused by the modified clearance to the adjacent vehicle components * Adverse vehicle steering stability caused by the modified scrub radius * Damage to the vehicle caused by the modified ground clearance * Speedometer and odometer inaccuracy Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of the following conditions exist: * The wheel has elongated bolt holes. * The wheel/nuts, or bolts if applicable, loosen repeatedly. Steel wheel identification is stamped into the wheel near the valve stem. Aluminum wheel identification is cast into the inboard side of the wheel. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1401 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Guidelines Warning To avoid personal injury when exposed to plastic media blast, hand and/or lathe sanding dust, primer, color coat, and clearcoat, you must work in a properly ventilated area, wearing an approved respirator, eye protection, earplugs and protective gloves and clothing. Evaluating Damage Note: * Inspect the wheel for corrosion, scrapes, gouges, etc. Damage MUST NOT be deeper than what can be sanded or polished off. * Inspect the wheel for cracks. If cracks are found, discard the wheel. * ALL wheels with bent rim flanges must not be repaired or refinished. * The re-machining and the re-clear coating of aluminum wheels is not recommended in the dealer environment due to concerns of repair durability. * Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Aluminum Wheel Refinishing General Recommendations/Options * Painted aluminum wheels use a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. (See option number 1). * If the clearcoat is damaged, it is possible to refinish with clearcoat only, however, the required refinishing process cannot be performed in the dealer environment. Refer to Refinishers Responsibility (Repair option number 2). * Re-plating of chrome-plated aluminum wheels is not recommended. Repair Option Number 1 Material Required/Information Resources * The Paint Manufacturer's Color Book * Refer to the latest GM Approved Refinish Materials Booklet (GM 4901 MD-2005) for specific products for aluminum refinishing. * To access the booklet. Click on GM Collision Parts. Click on GM Technical Repair Information, select Paint Shop. * A Color Compatibility chart is also at this site defining what colors are used on what models. Note: Chemical strippers are not recommended. * Refer to specific Paint Manufacturers for refinish procedures and process pertaining to "Aluminum Refinishing". The procedure requires the wheel surface to be plastic media blasted to remove old paint or clearcoat. General Color Selection * If the wheels being painted were previously clearcoated aluminum, and a painted aluminum look is desired, using Corsican Silver WAEQ9283 for a fine "aluminum-like" look, or Sparkle Silver WA9967 for a very bright look. Body color is another option to the customer that may also be used. * Some specific colors may be recommended on certain models. * If painting wheels that were previously clearcoated aluminum, it is recommended that all 4 wheels and their center caps be refinished to maintain color uniformity. General Refinishing Procedures - Removal 1. Remove the wheels from the vehicle. The tires may remain mounted on the wheels. 2. Remove the balance weights and mark their locations on the tire. 3. Remove excess grease, etc. from the wheels with wax and grease remover. 4. Have the wheels plastic media blasted to remove the clearcoat. Note: MASK OFF ALL MOUNTING SURFACES, whenever a wheel is refinished. The mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. 5. Clean and mask and paint the wheels. General Refinishing Procedures - Installation 1. Unmask the wheels. 2. Clean all wheel mounting surface of any corrosion, overspray, or dirt. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1402 Note: When re-balancing a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. 3. Install NEW coated balance weights at marked locations. Note: Use a torque stick on an impact wrench, or a torque wrench to consistently and uniformly fasten the wheel to the specified torque for the vehicle. The star pattern must be followed. 4. Install wheels on vehicle. Repair Option Number 2 - Outside Companies * Some outside companies are offering wheel refinishing services. One such company, Transwheel Corporation (800-892-3733), provides this service with GM guidelines. Other companies may also exist. * Any process that re-machines or otherwise remanufactures the wheel should not be used. * The wheel ID must be recorded and follow the wheel throughout the process to assure that the same wheel is returned. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is longer. * Paint and/or clearcoat must not be present on the following surfaces, the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. * A refinishers responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 1406 Wheel Bearing: Service and Repair Front Wheel Bearing and Hub Replacement Special Tools EN-45059 - Torque Angle Sensor Kit For equivalent regional tools, refer to Special Tools (See: Steering and Suspension/Suspension/Tools and Equipment/Front Suspension). Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the brake rotor. Refer to Front Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Front Brake Rotor Replacement). 3. Remove the wheel speed sensor screw (2). 4. Remove the wheel speed sensor (1) from the steering knuckle. 5. Remove the wheel drive shaft from the front wheel bearing/hub. Refer to Front Wheel Drive Shaft Replacement - Left Side (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Front Wheel Drive Shaft Replacement - Left Side) and/or Front Wheel Drive Shaft Replacement - Right Side (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Front Wheel Drive Shaft Replacement - Right Side). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 1407 6. Remove and DISCARD the front wheel bearing/hub bolts (1). 7. Remove the front wheel bearing/hub (1) and front brake shield (2) from the steering knuckle. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 1408 1. Position the front brake shield (2) and front wheel bearing/hub (1) assembly in the steering knuckle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the NEW front wheel bearing/hub bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 1409 3. Tighten the bearing/hub bolts (1) in 3 passes. Use the EN-45059 - angle meter. * First pass to 90 Nm (66 lb ft) * Second pass to 60° * Third pass to 15° 4. Install the wheel drive shaft at the front wheel bearing/hub. Refer to Front Wheel Drive Shaft Replacement - Left Side (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Front Wheel Drive Shaft Replacement - Left Side) or Front Wheel Drive Shaft Replacement - Right Side (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Front Wheel Drive Shaft Replacement - Right Side). 5. Install the wheel speed sensor (1) to the steering knuckle. 6. Install the wheel speed sensor screw (2) and tighten to 6 Nm (53 lb in). 7. Install the brake rotor. Refer to Front Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Front Brake Rotor Replacement). 8. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Wheel Drive Shaft Nut First Pass......................................................................................................... ............................................................................................150 Nm (111 lb ft) Release....................... .............................................................................................................................................................. ............................................45° Third Pass............................................................................................................................................ .......................................................250 Nm (184 lb ft) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Nuts........................................................................................................................................... .......................................................140 Nm (103 lb ft) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 1419 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the wheel bearing/hub. Refer to Rear Wheel Bearing and Hub Replacement (Disc Brakes) (See: Wheel Hub/Service and Repair/Rear Suspension). 4. Release the wheel stud (1) from the bearing hub with the hydraulic press and DISCARD the stud. Installation Procedure 1. Install a NEW stud into the bearing/hub assembly (2). Add enough washers (3) in order to draw the stud into the hub. 2. Install and tighten a wheel nut (1) until the head of the wheel stud is fully seated against the back of the bearing/hub flange (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 1420 3. Remove the wheel nut (1) and the washers (3). 4. Install the wheel bearing/hub (2). Refer to Rear Wheel Bearing and Hub Replacement (Disc Brakes) (See: Wheel Hub/Service and Repair/Rear Suspension). 5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Note: The use of a LOW PROFILE LIFT ARMS SYSTEM may be required to avoid unwanted contact with the vehicle's body and structure depending on lifting equipment used. Refer to the manufacture's recommendation for their applications of low profile lift arms system for their lifting equipment. Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Danger: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle contents. Vehicle Lifting - Frame Contact Lift Front Lift Pads When lifting the vehicle with a frame-contact lift, place the front lift pads on the rocker outer panel weld flange, as shown Rear Lift Pads Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Page 1424 When lifting the vehicle with a frame-contact lift, place the rear lift pads on the rocker outer panel weld flange, as shown. Vehicle Jacking Caution: When you are jacking the vehicle at the front locations, be certain that the jack or the jack lift pad does not contact the front fascia, front fascia air dam, or the front fenders. If such contact occurs, vehicle damage may result. When jacking at selected front locations additional clearance may be required for the jacking points. Note: When you are lifting a vehicle with a service jack, block the wheels at the opposite end from which you are lifting. Use jack stands to provide additional support. Front of Vehicle When using a service jack under the front of the vehicle use one of the following locations: Place the service jack pad in the same location as shown for the front lift pads. Rear of Vehicle Note: Place jackstands ONLY under strong and stable vehicle structures. Place the service jack pad in the same location as shown for the rear lift pads. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle Variable Valve Timing Actuator: Customer Interest Engine - Lack of Power with Multiple DTCs or Rattle TECHNICAL Bulletin No.: 10-06-04-016 Date: December 20, 2010 Subject: Engine Lack of Power with DTCs P0011, P0014, P000A, P000B, P0012, P0015 or Engine Rattle Noise (Remove Oil Filters from Intake and Exhaust Camshaft Position Actuator Solenoid Valves) Models: 2008-2011 Chevrolet Aveo 2011 Chevrolet Cruze (US and Canada) 2009-2011 Chevrolet Cruze (Export Only) 2008-2009 Pontiac G3, Wave 2008-2009 Saturn Astra Condition Some customers may comment on lack of power with the following DTCs or an engine rattle noise from the sprockets. Cruze GEN3 1.6/1.8D - P0011: Intake Camshaft Position (CMP) System Performance - P0014: Exhaust Camshaft Position (CMP) System Performance - P000A: Intake Camshaft Position System Slow Response - P000B: Exhaust Camshaft Position System Slow Response Aveo GEN3 1.4D - P0012: Intake Camshaft Position (CMP) System Performance Bank 1-Retarded - P0015: Exhaust Camshaft Position (CMP) System Performance Bank 1-Retarded Aveo/G3/Wave Gen3 1.6D - P0011: Intake Camshaft Position (CMP) System Performance Bank 1 - P0014: Exhaust Camshaft Position (CMP) System Performance Bank 1 Correction Remove four oil filters from the intake and exhaust camshaft position actuator solenoid valves. 1. Open the hood. 2. Disconnect the negative battery cable. 3. Disconnect the camshaft position actuator solenoid valve connectors. 4. Remove the power steering line bracket bolt and reposition the bracket (for 1.6/1.8L only). 5. Disconnect PCV pipe and reposition (for 1.6/1.8L only). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 1436 6. Remove the camshaft position actuator solenoid valve bolts. 7. Remove the camshaft position actuator solenoid valves and seals. 8. Check whether the filter is broken or not (1). 9. Remove the four filters (intake and exhaust). 1. Broken Filter: Remove filter with a blunt tool. 2. Unbroken Filter 1. Locate the filter hinge between the holes. 2. Cut the filter hinge slightly. Caution Do not scratch the valve surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 1437 3. Remove the filter with a blunt tool. 10. Install the camshaft position actuator solenoid valves and seals. Coat the seal with clean engine oil prior to installation. 11. Install the camshaft position actuator solenoid valve bolts. Tighten Tighten the bolts to 6 Nm (53 lb in). 12. Connect the camshaft position actuator solenoid valve connectors. 13. Reposition and install the PCV pipe (for 1.6/1.8 only). 14. Reposition the power steering bracket and install the power steering line bracket bolt (for 1.6/1.8 only). 15. Connect the negative battery cable. Note If an engine rattle noise is heard after removing the filters, refer to SI for further diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle Variable Valve Timing Actuator: All Technical Service Bulletins Engine - Lack of Power with Multiple DTCs or Rattle TECHNICAL Bulletin No.: 10-06-04-016 Date: December 20, 2010 Subject: Engine Lack of Power with DTCs P0011, P0014, P000A, P000B, P0012, P0015 or Engine Rattle Noise (Remove Oil Filters from Intake and Exhaust Camshaft Position Actuator Solenoid Valves) Models: 2008-2011 Chevrolet Aveo 2011 Chevrolet Cruze (US and Canada) 2009-2011 Chevrolet Cruze (Export Only) 2008-2009 Pontiac G3, Wave 2008-2009 Saturn Astra Condition Some customers may comment on lack of power with the following DTCs or an engine rattle noise from the sprockets. Cruze GEN3 1.6/1.8D - P0011: Intake Camshaft Position (CMP) System Performance - P0014: Exhaust Camshaft Position (CMP) System Performance - P000A: Intake Camshaft Position System Slow Response - P000B: Exhaust Camshaft Position System Slow Response Aveo GEN3 1.4D - P0012: Intake Camshaft Position (CMP) System Performance Bank 1-Retarded - P0015: Exhaust Camshaft Position (CMP) System Performance Bank 1-Retarded Aveo/G3/Wave Gen3 1.6D - P0011: Intake Camshaft Position (CMP) System Performance Bank 1 - P0014: Exhaust Camshaft Position (CMP) System Performance Bank 1 Correction Remove four oil filters from the intake and exhaust camshaft position actuator solenoid valves. 1. Open the hood. 2. Disconnect the negative battery cable. 3. Disconnect the camshaft position actuator solenoid valve connectors. 4. Remove the power steering line bracket bolt and reposition the bracket (for 1.6/1.8L only). 5. Disconnect PCV pipe and reposition (for 1.6/1.8L only). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 1443 6. Remove the camshaft position actuator solenoid valve bolts. 7. Remove the camshaft position actuator solenoid valves and seals. 8. Check whether the filter is broken or not (1). 9. Remove the four filters (intake and exhaust). 1. Broken Filter: Remove filter with a blunt tool. 2. Unbroken Filter 1. Locate the filter hinge between the holes. 2. Cut the filter hinge slightly. Caution Do not scratch the valve surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 1444 3. Remove the filter with a blunt tool. 10. Install the camshaft position actuator solenoid valves and seals. Coat the seal with clean engine oil prior to installation. 11. Install the camshaft position actuator solenoid valve bolts. Tighten Tighten the bolts to 6 Nm (53 lb in). 12. Connect the camshaft position actuator solenoid valve connectors. 13. Reposition and install the PCV pipe (for 1.6/1.8 only). 14. Reposition the power steering bracket and install the power steering line bracket bolt (for 1.6/1.8 only). 15. Connect the negative battery cable. Note If an engine rattle noise is heard after removing the filters, refer to SI for further diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Page 1445 Variable Valve Timing Actuator: Description and Operation Camshaft Actuator System Description Circuit/System Description The camshaft position actuator solenoid valve - intake and camshaft position actuator solenoid valve - exhaust system enables the engine control module (ECM) to change camshaft timing while the engine is running. The camshaft position actuator assembly varies camshaft position in response to directional changes in oil pressure. The camshaft position actuator solenoid valve Intake and camshaft position actuator solenoid valve - exhaust controls the oil pressure that is applied to advance or retard the camshaft. Modifying camshaft timing under changing engine demand provides better balance between the following performance concerns: * Engine power output * Fuel economy * Lower exhaust emissions The camshaft position actuator solenoid valve - intake and camshaft position actuator solenoid valve - exhaust is controlled by the ECM. The crankshaft position sensor and the camshaft position sensor - intake and camshaft position sensor - exhaust are used to monitor changes in camshaft position. The ECM uses information from the following sensors in order to calculate the desired camshaft position: * Engine coolant temperature (ECT) sensor * Mass air flow (MAF) sensor * Throttle position sensor * Vehicle speed sensor (VSS) Camshaft Position Actuator System Operation The ECM operates the camshaft position actuator solenoid valve - intake and camshaft position actuator solenoid valve - exhaust by pulse width modulation (PWM) of the solenoid coil. The higher the PWM duty cycle, the larger the change in camshaft timing. Oil pressure that is applied to the advance side of the fixed vanes will rotate the camshaft in a clockwise direction. The clockwise movement of the camshaft will advance the timing up to a maximum of 21°. When oil pressure is applied to the return side of the vanes, the camshaft will rotate counterclockwise until returning to 0°. Oil flowing to the camshaft position actuator solenoid valve - intake and camshaft position actuator solenoid valve - exhaust housing from the camshaft position actuator solenoid valve - Intake and camshaft position actuator solenoid valve - exhaust advance passage applies pressure to the advance side of the vane wheel in the camshaft position actuator assembly. At the same time the camshaft position actuator solenoid valve - Intake and camshaft position actuator solenoid valve exhaust retard passage is open, allowing oil pressure to decrease on the retard side of the vane wheel. These two simultaneous actions cause the vane wheel to rotate clockwise, advancing camshaft advance timing. When the oil flowing to the camshaft position actuator solenoid valve - Intake and camshaft position actuator solenoid valve - exhaust housing is from the camshaft position actuator solenoid valve Intake and camshaft position actuator solenoid valve - exhaust retard passage, oil pressure is applied to the retard side of the vane wheel. Because the solenoid advance passage is open, allowing oil pressure to decrease on the advance side of the vane wheel, the camshaft position retards. The ECM can also command the camshaft position actuator solenoid valve - Intake and camshaft position actuator solenoid valve - exhaust to stop oil flow from both passages in order to hold the current camshaft position. The ECM is continuously comparing camshaft position sensor - intake and camshaft position sensor - exhaust input with camshaft position actuator solenoid valve Intake and camshaft position actuator solenoid valve - exhaust input in order to monitor camshaft position and detect any system malfunctions. The following table provides camshaft phase commands for common driving conditions: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Service and Repair Variable Valve Timing Solenoid: Service and Repair Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure 1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.4L LUH and LUJ) (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 2. Disconnect the intake camshaft position actuator solenoid valve wiring harness plug (3). 3. Disconnect the exhaust camshaft position actuator solenoid valve wiring harness plug (2). 4. Unclip ECM wiring harness (1) from camshaft cover. 5. Remove the 4 camshaft position actuator solenoid valve bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Service and Repair > Page 1449 6. Carefully rotate the intake camshaft position actuator solenoid valve (1) counter clockwise as shown. 7. Carefully rotate the exhaust camshaft position actuator solenoid valve (2) clockwise as shown. Caution: The camshaft position actuator solenoid valves must be kept parallel to the engine front cover during removal and installation. The camshaft position actuator solenoid valves can be damaged if they become wedged or stuck during this process. 8. Carefully remove the 2 camshaft position actuator solenoid valves (2) and the seal rings (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Service and Repair > Page 1450 Caution: The camshaft position actuator solenoid valves must be kept parallel to the engine front cover during removal and installation. The camshaft position actuator solenoid valves can be damaged if they become wedged or stuck during this process. Note: Lubricate the seal rings with oil in order to make the installation easier. 1. Carefully install the 2 camshaft position actuator solenoid valves (2) and the 2 seal rings (1) by gently pressing into position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 4 camshaft position actuator solenoid valve bolts (1) and tighten to 8 Nm (71 lb in). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Service and Repair > Page 1451 3. The 2 camshaft position actuator solenoid valves should be installed in the position as shown (1) and (2). 4. Clip ECM wiring harness (1) to camshaft cover. 5. Connect the exhaust camshaft position actuator solenoid valve wiring harness plug (2). 6. Connect the intake camshaft position actuator solenoid valve wiring harness plug (3). 7. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.4L LUH and LUJ) (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications All 4 cylinders must be tested to obtain valid test results. Record the readings. Maximum pressure differential............................................................................................................. .......................................................100 kPa (14.5 psi) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1455 Compression Check: Testing and Inspection Engine Compression Test Special Tools EN-48248 - Cylinder Compression Pressure Gauge For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement (1.4L LUH and LUJ) (See: Powertrain Management/Fuel Delivery and Air Induction/Throttle Body/Service and Repair/Removal and Replacement). 2. Remove the spark plugs. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). 3. Remove the relay holder cover. 4. Remove the fuel pump relay. Note: The engine cranking time for the compression test should be less then 10 seconds and at 30 second intervals. 5. Crank the engine with the starter motor for 5 seconds to remove any foreign substances from the cylinders. 6. Prior to taking a compression reading, verify the cranking speed is greater than 300 RPM. If the cranking speed is below 300 RPM, repair the slow cranking speed condition before continuing with the compression test. 7. Install EN-48248 - gauge in the spark plug bore for the cylinder that is being checked. 8. Using the vehicle's starter motor, rotate or crank the engine for 4 compression strokes, puffs, for the cylinder being tested. 9. Observe the compression gauge and note the reading as the compression test is being performed. A normal cylinder reading will be indicated if compression builds up quickly and evenly to the specified level. An abnormal reading will be indicated if compression is low on the first compression stroke, starts increasing on the following compression strokes but does not reach the specified level. 10. Record the compression reading for the cylinder just tested. 11. Repeat steps for all remaining cylinders. All 4 cylinders must be tested to obtain valid test results. Record the readings. 12. Maximum pressure differential 100 kPa (14.5 psi). Installation Procedure 1. Install the fuel pump relay. 2. Install the relay holder cover. 3. Install the spark plugs. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). 4. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement (1.4L LUH and LUJ) (See: Powertrain Management/Fuel Delivery and Air Induction/Throttle Body/Service and Repair/Removal and Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Tighten the intake camshaft sprocket bolt (4) while holding the hexagon (1) of the intake camshaft to.................................................................................................................................50 Nm (37 lb ft) while holding the hexagon (1) of the intake camshaft an additional....................................................................................................................................60° Tighten the exhaust camshaft sprocket bolt while holding the hexagon of the exhaust camshaft to....................................................................................................................................50 Nm (37 lb ft) while holding the hexagon of the exhaust camshaft an additional.......................................................................................................................................60° Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Page 1460 Camshaft Gear/Sprocket: Service and Repair Camshaft Intake Sprocket Replacement Special Tool EN-955-1 - Fixing Pin from EN-955 - Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Open the hood. 2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.4L LUH and LUJ) (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 3. Remove the camshaft cover. Refer to Camshaft Cover Replacement (1.4L LUH and LUJ) (See: Cylinder Head Assembly/Valve Cover/Service and Repair). 4. Remove the 2 camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid Valve Removal (See: Service and Repair/Overhaul/25. Camshaft Position Actuator Solenoid Valve Removal). 5. Adjust the engine to TDC. Refer to Camshaft Timing Chain Inspection (See: Service and Repair/Overhaul/3. Camshaft Timing Chain Inspection). 6. Remove the timing chain tensioner plug (1) from the engine front cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Page 1461 7. Install a wrench (1) to the hexagon of the intake camshaft and rotate it in direction of the arrow in order to apply tension to the timing chain and hold. 8. Install EN-955-1 - pin (2) to the timing chain tensioner bore (1) to secure it in place. 9. Remove the wrench from the intake camshaft. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Page 1462 10. Remove the 2 upper timing chain guide bolts (1). 11. Remove the upper timing chain guide (2). 12. Loosen the intake camshaft sprocket bolt (2) while holding the hexagon of the intake camshaft with a wrench (1). 13. Loosen the exhaust camshaft sprocket bolt while holding the hexagon of the exhaust camshaft with a wrench. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Page 1463 14. Remove the 2 camshaft sprocket bolts (2) and the 2 camshaft position exciter wheels (1). 15. Remove the 2 camshaft sprockets (2) along with the timing chain (1) and place it in the engine front cover. 16. Remove the intake camshaft sprocket. Installation Procedure 1. Insert the intake camshaft sprocket to the engine to engine front cover and timing chain. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Page 1464 2. Install the 2 camshaft sprockets (2) along with the timing chain (1) to the camshafts. 3. Install the 2 camshaft sprocket bolts (2) and the 2 camshaft position exciter wheels (1). 4. Remove EN-955-1 - pin to apply tension to the timing chain. Note: Engine must be adjusted to TDC. 5. Tighten the 2 camshaft sprockets. Refer to Camshaft Timing Chain Adjustment (See: Service and Repair/Overhaul/4. Camshaft Timing Chain Adjustment). 6. Remove all special tools for timing chain adjustment. Refer to Camshaft Timing Chain Adjustment (See: Service and Repair/Overhaul/4. Camshaft Timing Chain Adjustment). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Page 1465 7. Install the upper timing chain guide (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 8. Install the 2 upper timing chain guide bolts (1) and tighten to 8 Nm (71 lb in). 9. Install the 2 camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid Valve Installation (See: Service and Repair/Overhaul/74. Camshaft Position Actuator Solenoid Valve Installation) 10. Install the camshaft cover. Refer to Camshaft Cover Replacement (1.4L LUH and LUJ) (See: Cylinder Head Assembly/Valve Cover/Service and Repair). 11. Install the timing chain tensioner plug and tighten to 50 Nm (37 lb ft). 12. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.4L LUH and LUJ) (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 13. Check and correct engine oil level. 14. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Exhaust Sprocket Replacement Camshaft: Service and Repair Camshaft Exhaust Sprocket Replacement Camshaft Exhaust Sprocket Replacement Special Tool EN-955-1 - Fixing Pin from EN-955 - Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Open the hood. 2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.4L LUH and LUJ) (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 3. Remove the camshaft cover. Refer to Camshaft Cover Replacement (1.4L LUH and LUJ) (See: Cylinder Head Assembly/Valve Cover/Service and Repair). 4. Remove the 2 camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid Valve Removal (See: Service and Repair/Overhaul/25. Camshaft Position Actuator Solenoid Valve Removal). 5. Adjust the engine to TDC. Refer to Camshaft Timing Chain Inspection (See: Service and Repair/Overhaul/3. Camshaft Timing Chain Inspection). 6. Remove the timing chain tensioner plug (1) from the engine front cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Exhaust Sprocket Replacement > Page 1470 7. Install a wrench (1) to the hexagon of the intake camshaft and rotate it in direction of the arrow in order to apply tension to the timing chain and hold. 8. Install EN-955-1 - pin (2) to the timing chain tensioner bore (1) to secure it in place. 9. Remove the wrench from the intake camshaft. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Exhaust Sprocket Replacement > Page 1471 10. Remove the 2 upper timing chain guide bolts (1). 11. Remove the upper timing chain guide (2). 12. Loosen the intake camshaft sprocket bolt (2) while holding the hexagon of the intake camshaft with a wrench (1). 13. Loosen the exhaust camshaft sprocket bolt while holding the hexagon of the exhaust camshaft with a wrench. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Exhaust Sprocket Replacement > Page 1472 14. Remove the 2 camshaft sprocket bolts (2) and the 2 camshaft position exciter wheels (1). 15. Remove the 2 camshaft sprockets (2) along with the timing chain (1) and place it in the engine front cover. 16. Remove the exhaust camshaft sprocket. Installation Procedure 1. Insert the exhaust camshaft sprocket to the engine front cover and timing chain. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Exhaust Sprocket Replacement > Page 1473 2. Install the 2 camshaft sprockets (2) along with the timing chain (1) to the camshafts. 3. Install the 2 camshaft sprocket bolts (2) and the 2 camshaft position exciter wheels (1). 4. Remove EN-955-1 - pin to apply tension to the timing chain. Note: Engine must be adjusted to TDC. 5. Tighten the 2 camshaft sprockets. Refer to Camshaft Timing Chain Adjustment (See: Service and Repair/Overhaul/4. Camshaft Timing Chain Adjustment). 6. Remove all special tools for timing chain adjustment. Refer to Camshaft Timing Chain Adjustment (See: Service and Repair/Overhaul/4. Camshaft Timing Chain Adjustment). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Exhaust Sprocket Replacement > Page 1474 7. Install the upper timing chain guide (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the 2 upper timing chain guide bolts (1) and tighten to 8 Nm (71 lb in). 9. Install the 2 camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid Valve Installation (See: Service and Repair/Overhaul/74. Camshaft Position Actuator Solenoid Valve Installation) 10. Install the camshaft cover. Refer to Camshaft Cover Replacement (1.4L LUH and LUJ) (See: Cylinder Head Assembly/Valve Cover/Service and Repair). 11. Install the timing chain tensioner plug and tighten to 50 Nm (37 lb ft). 12. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.4L LUH and LUJ) (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 13. Check and correct engine oil level. 14. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Exhaust Sprocket Replacement > Page 1475 Camshaft: Service and Repair Exhaust Camshaft Replacement Exhaust Camshaft Replacement Removal Procedure 1. Remove the camshaft exhaust sprocket. Refer to Camshaft Exhaust Sprocket Replacement (See: Camshaft Exhaust Sprocket Replacement). 2. Remove the camshaft bearing cap bolts in a spiral sequence as shown one turn at a time until there is no spring tension pushing on the camshaft. Note: Mind the markings on the camshaft bearing caps to ensure they will be installed in the same position. 3. Remove the 10 camshaft bearing cap bolts (1). 4. Remove the 5 camshaft bearing caps (2). 5. Remove the exhaust camshaft (3). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Exhaust Sprocket Replacement > Page 1476 Note: Mind the markings on the camshaft bearing caps. Camshaft bearing caps should be installed in their original position. 1. Lubricate camshaft and camshaft bearing caps with engine oil. 2. Install the exhaust camshaft (3). 3. Install the 5 camshaft bearing caps (2). 4. Install the 10 camshaft bearing cap bolts (1) and handtighten. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Tighten the camshaft bearing cap bolts one turn a time to avoid shape distortion of the camshaft. 5. Tighten the camshaft bearing cap bolts one turn at a time in a spiral sequence as shown to 8 Nm (71 lb in). 6. Install the camshaft exhaust sprocket. Refer to Camshaft Exhaust Sprocket Replacement (See: Camshaft Exhaust Sprocket Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Exhaust Sprocket Replacement > Page 1477 Camshaft: Service and Repair Intake Camshaft Replacement Intake Camshaft Replacement Removal Procedure 1. Remove the camshaft intake sprocket. Refer to Camshaft Intake Sprocket Replacement (See: Camshaft Gear/Sprocket/Service and Repair). 2. Remove the camshaft bearing cap bolts in a spiral sequence as shown one turn at a time until there is no spring tension pushing on the camshaft. Note: Mind the markings on the camshaft bearing caps to ensure they will be installed in the same position. 3. Remove the 10 camshaft bearing cap bolts (1). 4. Remove the 5 camshaft bearing caps (2). 5. Remove the intake camshaft (3). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Exhaust Sprocket Replacement > Page 1478 Note: Mind the markings on the camshaft bearing caps. Camshaft bearing caps should be installed in their original position. 1. Lubricate camshaft and camshaft bearing caps with engine oil. 2. Install the intake camshaft (3). 3. Install the 5 camshaft bearing caps (2). 4. Install the 10 camshaft bearing cap bolts (1) and handtighten. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Tighten the camshaft bearing cap bolts one turn a time to avoid shape distortion of the camshaft. 5. Tighten the camshaft bearing cap bolts one turn at a time in a spiral sequence as shown to 8 Nm (71 lb in). 6. Install camshaft intake sprocket. Refer to Camshaft Intake Sprocket Replacement (See: Camshaft Gear/Sprocket/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service Precautions Lifter / Lash Adjuster: Service Precautions Valve Lifter Priming Caution Caution: Ensure each valve lifter is filled with clean engine oil and the valve lifter does not tip over (plunger down) before the installation of the valve lifters. The loss of oil in the valve lifter lower pressure chamber or the dry stroking/cycling of the valve lifter plunger will allow air to travel into the high pressure chamber of the valve lifter. Air in the high pressure chamber of the valve lifter may not be purged causing extensive engine component damage. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Hydraulic Valve Lash Adjuster Arm Replacement Lifter / Lash Adjuster: Service and Repair Hydraulic Valve Lash Adjuster Arm Replacement Hydraulic Valve Lash Adjuster Arm Replacement Removal Procedure 1. Remove the intake camshaft. Refer to Intake Camshaft Replacement (See: Camshaft/Service and Repair/Intake Camshaft Replacement). 2. Remove the exhaust camshaft. Refer to Exhaust Camshaft Replacement (See: Camshaft/Service and Repair/Exhaust Camshaft Replacement). Note: Mind the installation position of the hydraulic valve lash adjuster arms. 3. Remove the 16 hydraulic valve lash adjuster arms (1). Installation Procedure Note: Hydraulic valve lash adjuster arms should be installed in their original position Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Hydraulic Valve Lash Adjuster Arm Replacement > Page 1484 1. Lubricate the hydraulic valve lash adjuster arms with engine oil. 2. Install the 16 hydraulic valve lash adjuster arms (1). 3. Install the exhaust camshaft. Refer to Exhaust Camshaft Replacement (See: Camshaft/Service and Repair/Exhaust Camshaft Replacement). 4. Install the intake camshaft. Refer to Intake Camshaft Replacement (See: Camshaft/Service and Repair/Intake Camshaft Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Hydraulic Valve Lash Adjuster Arm Replacement > Page 1485 Lifter / Lash Adjuster: Service and Repair Hydraulic Valve Lash Adjuster Replacement Hydraulic Valve Lash Adjuster Replacement Removal Procedure 1. Remove the 16 hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm Replacement (See: Hydraulic Valve Lash Adjuster Arm Replacement). Note: Mind the installation position of the hydraulic valve lash adjusters. 2. Remove the 16 hydraulic valve lash adjusters (1). Installation Procedure Note: Mind the installation position of the hydraulic valve lash adjusters. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Hydraulic Valve Lash Adjuster Arm Replacement > Page 1486 1. Lubricate the hydraulic valve lash adjusters with engine oil. 2. Install the 16 hydraulic valve lash adjusters (1). 3. Install the 16 hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm Replacement (See: Hydraulic Valve Lash Adjuster Arm Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle Variable Valve Timing Actuator: Customer Interest Engine - Lack of Power with Multiple DTCs or Rattle TECHNICAL Bulletin No.: 10-06-04-016 Date: December 20, 2010 Subject: Engine Lack of Power with DTCs P0011, P0014, P000A, P000B, P0012, P0015 or Engine Rattle Noise (Remove Oil Filters from Intake and Exhaust Camshaft Position Actuator Solenoid Valves) Models: 2008-2011 Chevrolet Aveo 2011 Chevrolet Cruze (US and Canada) 2009-2011 Chevrolet Cruze (Export Only) 2008-2009 Pontiac G3, Wave 2008-2009 Saturn Astra Condition Some customers may comment on lack of power with the following DTCs or an engine rattle noise from the sprockets. Cruze GEN3 1.6/1.8D - P0011: Intake Camshaft Position (CMP) System Performance - P0014: Exhaust Camshaft Position (CMP) System Performance - P000A: Intake Camshaft Position System Slow Response - P000B: Exhaust Camshaft Position System Slow Response Aveo GEN3 1.4D - P0012: Intake Camshaft Position (CMP) System Performance Bank 1-Retarded - P0015: Exhaust Camshaft Position (CMP) System Performance Bank 1-Retarded Aveo/G3/Wave Gen3 1.6D - P0011: Intake Camshaft Position (CMP) System Performance Bank 1 - P0014: Exhaust Camshaft Position (CMP) System Performance Bank 1 Correction Remove four oil filters from the intake and exhaust camshaft position actuator solenoid valves. 1. Open the hood. 2. Disconnect the negative battery cable. 3. Disconnect the camshaft position actuator solenoid valve connectors. 4. Remove the power steering line bracket bolt and reposition the bracket (for 1.6/1.8L only). 5. Disconnect PCV pipe and reposition (for 1.6/1.8L only). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 1495 6. Remove the camshaft position actuator solenoid valve bolts. 7. Remove the camshaft position actuator solenoid valves and seals. 8. Check whether the filter is broken or not (1). 9. Remove the four filters (intake and exhaust). 1. Broken Filter: Remove filter with a blunt tool. 2. Unbroken Filter 1. Locate the filter hinge between the holes. 2. Cut the filter hinge slightly. Caution Do not scratch the valve surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 1496 3. Remove the filter with a blunt tool. 10. Install the camshaft position actuator solenoid valves and seals. Coat the seal with clean engine oil prior to installation. 11. Install the camshaft position actuator solenoid valve bolts. Tighten Tighten the bolts to 6 Nm (53 lb in). 12. Connect the camshaft position actuator solenoid valve connectors. 13. Reposition and install the PCV pipe (for 1.6/1.8 only). 14. Reposition the power steering bracket and install the power steering line bracket bolt (for 1.6/1.8 only). 15. Connect the negative battery cable. Note If an engine rattle noise is heard after removing the filters, refer to SI for further diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle Variable Valve Timing Actuator: All Technical Service Bulletins Engine - Lack of Power with Multiple DTCs or Rattle TECHNICAL Bulletin No.: 10-06-04-016 Date: December 20, 2010 Subject: Engine Lack of Power with DTCs P0011, P0014, P000A, P000B, P0012, P0015 or Engine Rattle Noise (Remove Oil Filters from Intake and Exhaust Camshaft Position Actuator Solenoid Valves) Models: 2008-2011 Chevrolet Aveo 2011 Chevrolet Cruze (US and Canada) 2009-2011 Chevrolet Cruze (Export Only) 2008-2009 Pontiac G3, Wave 2008-2009 Saturn Astra Condition Some customers may comment on lack of power with the following DTCs or an engine rattle noise from the sprockets. Cruze GEN3 1.6/1.8D - P0011: Intake Camshaft Position (CMP) System Performance - P0014: Exhaust Camshaft Position (CMP) System Performance - P000A: Intake Camshaft Position System Slow Response - P000B: Exhaust Camshaft Position System Slow Response Aveo GEN3 1.4D - P0012: Intake Camshaft Position (CMP) System Performance Bank 1-Retarded - P0015: Exhaust Camshaft Position (CMP) System Performance Bank 1-Retarded Aveo/G3/Wave Gen3 1.6D - P0011: Intake Camshaft Position (CMP) System Performance Bank 1 - P0014: Exhaust Camshaft Position (CMP) System Performance Bank 1 Correction Remove four oil filters from the intake and exhaust camshaft position actuator solenoid valves. 1. Open the hood. 2. Disconnect the negative battery cable. 3. Disconnect the camshaft position actuator solenoid valve connectors. 4. Remove the power steering line bracket bolt and reposition the bracket (for 1.6/1.8L only). 5. Disconnect PCV pipe and reposition (for 1.6/1.8L only). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 1502 6. Remove the camshaft position actuator solenoid valve bolts. 7. Remove the camshaft position actuator solenoid valves and seals. 8. Check whether the filter is broken or not (1). 9. Remove the four filters (intake and exhaust). 1. Broken Filter: Remove filter with a blunt tool. 2. Unbroken Filter 1. Locate the filter hinge between the holes. 2. Cut the filter hinge slightly. Caution Do not scratch the valve surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 1503 3. Remove the filter with a blunt tool. 10. Install the camshaft position actuator solenoid valves and seals. Coat the seal with clean engine oil prior to installation. 11. Install the camshaft position actuator solenoid valve bolts. Tighten Tighten the bolts to 6 Nm (53 lb in). 12. Connect the camshaft position actuator solenoid valve connectors. 13. Reposition and install the PCV pipe (for 1.6/1.8 only). 14. Reposition the power steering bracket and install the power steering line bracket bolt (for 1.6/1.8 only). 15. Connect the negative battery cable. Note If an engine rattle noise is heard after removing the filters, refer to SI for further diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Page 1504 Variable Valve Timing Actuator: Description and Operation Camshaft Actuator System Description Circuit/System Description The camshaft position actuator solenoid valve - intake and camshaft position actuator solenoid valve - exhaust system enables the engine control module (ECM) to change camshaft timing while the engine is running. The camshaft position actuator assembly varies camshaft position in response to directional changes in oil pressure. The camshaft position actuator solenoid valve Intake and camshaft position actuator solenoid valve - exhaust controls the oil pressure that is applied to advance or retard the camshaft. Modifying camshaft timing under changing engine demand provides better balance between the following performance concerns: * Engine power output * Fuel economy * Lower exhaust emissions The camshaft position actuator solenoid valve - intake and camshaft position actuator solenoid valve - exhaust is controlled by the ECM. The crankshaft position sensor and the camshaft position sensor - intake and camshaft position sensor - exhaust are used to monitor changes in camshaft position. The ECM uses information from the following sensors in order to calculate the desired camshaft position: * Engine coolant temperature (ECT) sensor * Mass air flow (MAF) sensor * Throttle position sensor * Vehicle speed sensor (VSS) Camshaft Position Actuator System Operation The ECM operates the camshaft position actuator solenoid valve - intake and camshaft position actuator solenoid valve - exhaust by pulse width modulation (PWM) of the solenoid coil. The higher the PWM duty cycle, the larger the change in camshaft timing. Oil pressure that is applied to the advance side of the fixed vanes will rotate the camshaft in a clockwise direction. The clockwise movement of the camshaft will advance the timing up to a maximum of 21°. When oil pressure is applied to the return side of the vanes, the camshaft will rotate counterclockwise until returning to 0°. Oil flowing to the camshaft position actuator solenoid valve - intake and camshaft position actuator solenoid valve - exhaust housing from the camshaft position actuator solenoid valve - Intake and camshaft position actuator solenoid valve - exhaust advance passage applies pressure to the advance side of the vane wheel in the camshaft position actuator assembly. At the same time the camshaft position actuator solenoid valve - Intake and camshaft position actuator solenoid valve exhaust retard passage is open, allowing oil pressure to decrease on the retard side of the vane wheel. These two simultaneous actions cause the vane wheel to rotate clockwise, advancing camshaft advance timing. When the oil flowing to the camshaft position actuator solenoid valve - Intake and camshaft position actuator solenoid valve - exhaust housing is from the camshaft position actuator solenoid valve Intake and camshaft position actuator solenoid valve - exhaust retard passage, oil pressure is applied to the retard side of the vane wheel. Because the solenoid advance passage is open, allowing oil pressure to decrease on the advance side of the vane wheel, the camshaft position retards. The ECM can also command the camshaft position actuator solenoid valve - Intake and camshaft position actuator solenoid valve - exhaust to stop oil flow from both passages in order to hold the current camshaft position. The ECM is continuously comparing camshaft position sensor - intake and camshaft position sensor - exhaust input with camshaft position actuator solenoid valve Intake and camshaft position actuator solenoid valve - exhaust input in order to monitor camshaft position and detect any system malfunctions. The following table provides camshaft phase commands for common driving conditions: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair Connecting Rod Bearing: Service and Repair Piston, Connecting Rod, and Bearing Replacement Special Tools EN-470-B - Angular Torque Wrench For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Open the hood. 2. Remove the cylinder head. Refer to Cylinder Head Replacement (1.4L LUH and LUJ) (See: Cylinder Head Assembly/Service and Repair). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Remove the oil pan. Refer to Oil Pan Replacement (1.4L LUH and LUJ) (See: Engine Lubrication/Oil Pan/Service and Repair). Note: Mark the installation position of the connecting rod bearing caps. The connecting rod bearings and bearing caps must not be interchanged with other connecting rods. 5. Remove the 4 connecting rod bearing cap bolts (1) of cylinder 2 and 3. 6. Remove the 2 connecting rod bearing caps (2) and the 2 connecting rod bearings of cylinder 2 and 3. 7. Rotate the crankshaft 180°. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Page 1509 8. Remove the 4 connecting rod bearing cap bolts (1) of cylinder 1 and 4. 9. Remove the 2 connecting rod bearing caps (2) and the 2 connecting rod bearings of cylinder 1 and 4. 10. Remove the 4 pistons (1) and connecting rods (2) and the 4 upper connecting rod bearings (3) from the cylinder block. Installation Procedure 1. For cleaning and inspection procedure, refer to Piston, Connecting Rod, and Bearing Cleaning and Inspection (1.4L LUH and LUJ) (See: Service and Repair/Overhaul/46. Piston, Connecting Rod, and Bearing Cleaning and Inspection). 2. Assemble the NEW piston and connecting rod. Refer to Piston and Connecting Rod Assemble (1.4L LUH and LUJ) (See: Service and Repair/Overhaul/47. Piston and Connecting Rod Assemble). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Page 1510 3. Adjust the piston ring joints as followed: 1. Upper compression ring (1) 2. Lower compression ring (4) 3. Oilring (2) or (3) 4. Oilring spacer (5) 4. The arrow (1) on the piston head must point to the timing side. 5. The markings on the connecting rods (2) must point to the transmission side. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Page 1511 6. Lubricate the piston rings, piston, inner cylinder bore surface and a piston ring compressor with clean engine oil. 7. Install the piston ring compressor in order to compress the piston rings. 8. Install the pistons (1) in compound with connecting rods (2) and upper connecting rod bearings (3) to the engine block and to the crankshaft. Note: The flarings (arrows) on the connecting rod bearing caps must point to the transmission side. The connecting rod bearing caps must be installed in their original position. 9. Install the 2 connecting rod bearings and the 2 connecting rod bearing caps (2) of cylinder 1 and 4. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 10. Install the 4 connecting rod bearing cap bolts (1) and tighten in the following sequence: 1. Tighten the connecting rod bearing cap bolts to 25 Nm (18 lb ft). 2. Tighten the connecting rod bearing cap bolts an additional 25°. Use EN-470-B - wrench. 11. Rotate the crankshaft 180°. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Page 1512 Note: The flarings (arrows) on the connecting rod bearing caps must point to the transmission side. The connecting rod bearing caps must be installed in their original position. 12. Install the 2 connecting rod bearings and the 2 connecting rod bearing caps (2) of cylinder 3 and 2. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 13. Install the 4 connecting rod bearing cap bolts (1) and tighten in the following sequence: 1. Tighten the connecting rod bearing cap bolts to 25 Nm (18 lb ft). 2. Tighten the connecting rod bearing cap bolts an additional 45°. Use EN-470-B - wrench. 14. Install the oil pan Refer to Oil Pan Replacement (1.4L LUH and LUJ) (See: Engine Lubrication/Oil Pan/Service and Repair). 15. Lower the vehicle. 16. Install the cylinder head. Refer to Cylinder Head Replacement (1.4L LUH and LUJ) (See: Cylinder Head Assembly/Service and Repair). 17. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Connecting Rod Bearing Cap............................................................................................................... .......................................25 Nm + 45° (18 lb ft + 45°) Connecting Rod Bearing Journal Diameter Standard 42.971 mm - 42.987 mm 1.6918 in - 1.6924 in •Connecting Rod Bearing Journal Diameter Undersize 0.25 (blue) 42.721 mm -42.737 mm 1.6819 in - 1.6826 in •Connecting Rod Bearing Journal Diameter Undersize 0.5 (white) 42.471 mm -42.487 mm 1.6721 in - 1.6727 in •Connecting Rod Bearing Thickness Standard 1.490 mm - 1.500 mm 0.0587 in - 0.0591 in •Connecting Rod Bearing Thickness Undersize 0.25 1.615 mm - 1.625 mm 0.0636 in - 0.064 in •Connecting Rod Bearing Thickness Undersize 0.5 1.740 mm - 1.750 mm 0.0685 in - 0.0689 in •Connecting Rod Bearing Diameter Standard (upper and lower) 1.490 mm 1.500 mm 0.0587 in - 0.0591 in •Connecting Rod Bearing Diameter Undersize 0.25 (upper and lower) 1.615 mm - 1.625 mm 0.0636 in - 0.064 in •Connecting Rod Bearing Diameter Undersize 0.5 (upper and lower) 1.740 mm - 1.750 mm 0.0685 in - 0.0689 in •Connecting Rod Bearing Clearance 0.013 mm - 0.061 mm 0.0005 in - 0.0024 in Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1516 Connecting Rod: Service and Repair Piston, Connecting Rod, and Bearing Replacement Special Tools EN-470-B - Angular Torque Wrench For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Open the hood. 2. Remove the cylinder head. Refer to Cylinder Head Replacement (1.4L LUH and LUJ) (See: Cylinder Head Assembly/Service and Repair). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Remove the oil pan. Refer to Oil Pan Replacement (1.4L LUH and LUJ) (See: Engine Lubrication/Oil Pan/Service and Repair). Note: Mark the installation position of the connecting rod bearing caps. The connecting rod bearings and bearing caps must not be interchanged with other connecting rods. 5. Remove the 4 connecting rod bearing cap bolts (1) of cylinder 2 and 3. 6. Remove the 2 connecting rod bearing caps (2) and the 2 connecting rod bearings of cylinder 2 and 3. 7. Rotate the crankshaft 180°. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1517 8. Remove the 4 connecting rod bearing cap bolts (1) of cylinder 1 and 4. 9. Remove the 2 connecting rod bearing caps (2) and the 2 connecting rod bearings of cylinder 1 and 4. 10. Remove the 4 pistons (1) and connecting rods (2) and the 4 upper connecting rod bearings (3) from the cylinder block. Installation Procedure 1. For cleaning and inspection procedure, refer to Piston, Connecting Rod, and Bearing Cleaning and Inspection (1.4L LUH and LUJ) (See: Service and Repair/Overhaul/46. Piston, Connecting Rod, and Bearing Cleaning and Inspection). 2. Assemble the NEW piston and connecting rod. Refer to Piston and Connecting Rod Assemble (1.4L LUH and LUJ) (See: Service and Repair/Overhaul/47. Piston and Connecting Rod Assemble). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1518 3. Adjust the piston ring joints as followed: 1. Upper compression ring (1) 2. Lower compression ring (4) 3. Oilring (2) or (3) 4. Oilring spacer (5) 4. The arrow (1) on the piston head must point to the timing side. 5. The markings on the connecting rods (2) must point to the transmission side. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1519 6. Lubricate the piston rings, piston, inner cylinder bore surface and a piston ring compressor with clean engine oil. 7. Install the piston ring compressor in order to compress the piston rings. 8. Install the pistons (1) in compound with connecting rods (2) and upper connecting rod bearings (3) to the engine block and to the crankshaft. Note: The flarings (arrows) on the connecting rod bearing caps must point to the transmission side. The connecting rod bearing caps must be installed in their original position. 9. Install the 2 connecting rod bearings and the 2 connecting rod bearing caps (2) of cylinder 1 and 4. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 10. Install the 4 connecting rod bearing cap bolts (1) and tighten in the following sequence: 1. Tighten the connecting rod bearing cap bolts to 25 Nm (18 lb ft). 2. Tighten the connecting rod bearing cap bolts an additional 25°. Use EN-470-B - wrench. 11. Rotate the crankshaft 180°. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1520 Note: The flarings (arrows) on the connecting rod bearing caps must point to the transmission side. The connecting rod bearing caps must be installed in their original position. 12. Install the 2 connecting rod bearings and the 2 connecting rod bearing caps (2) of cylinder 3 and 2. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 13. Install the 4 connecting rod bearing cap bolts (1) and tighten in the following sequence: 1. Tighten the connecting rod bearing cap bolts to 25 Nm (18 lb ft). 2. Tighten the connecting rod bearing cap bolts an additional 45°. Use EN-470-B - wrench. 14. Install the oil pan Refer to Oil Pan Replacement (1.4L LUH and LUJ) (See: Engine Lubrication/Oil Pan/Service and Repair). 15. Lower the vehicle. 16. Install the cylinder head. Refer to Cylinder Head Replacement (1.4L LUH and LUJ) (See: Cylinder Head Assembly/Service and Repair). 17. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Crankshaft Tighten the 10 inner crankshaft bearing cap tie plate bolts in the sequence shown and to the following specifications: Tighten the inner crankshaft bearing cap tie plate bolts to 25 Nm (18 lb ft). Tighten the inner crankshaft bearing cap tie plate bolts an additional 60°. Use EN-470-B - wrench. Tighten the inner crankshaft bearing cap tie plate bolts an additional 15°. Use EN-470-B - wrench. Refer to Crankshaft and Bearing Installation. See: Service and Repair/Overhaul/60. Crankshaft and Bearing Installation Crankshaft Bearing Journal Standard Diameter (brown or green).............................................................................................................50.004 mm -50.017 mm (1.9687 in - 1.9692 in) Undersize 0.25 Diameter (brown/blue or green/blue)....................................................................................49.754 mm -49.767 mm (1.9588 in - 1.9593 in) Undersize 0.5 Diameter (brown/white or green/white)....................................................................................49.504 mm -49.517 mm (1.949 in - 1.9495 in) Width Standard.................................................................................................................. ............................23.000 mm -23.052 mm (0.9055 in - 0.9076 in) Width Undersize 0.25....................................................................................................................................23.200 mm -23.252 mm (0.9134 in - 0.9154 in) Width Undersize 0.4......................................................................................................................................23.400 mm -23.452 mm (0.9213 in - 0.9233 in) Crankshaft Bearing Mark 328N (brown) Thickness.................................................................................................................................1.989 mm -1.995 mm (0.0783 in - 0.0785 in) 329N (green) Thickness..................................................................................................................................1.995 mm -2.001 mm (0.0785 in - 0.0788 in) 330N - Thickness Undersize 0.25 (brown/blue)...............................................................................................2.114 mm - 2.120 mm (0.0832 in - 0.0835 in) 331 - Thickness Undersize 0.25 (green/blue)...................................................................................................2.120 mm - 2.126 mm (0.0835 in - 0.0837 in) 332 - Thickness Undersize 0.5 (brown/white)..................................................................................................2.239 mm - 2.245 mm (0.0881 in - 0.0884 in) 332 - Thickness Undersize 0.5 (green/white)....................................................................................................2.245 mm - 2.251 mm (0.0884 in - 0.0886 in) Crankshaft Bearing Clearance..........................................................................................................................0.007 mm 0.031 mm (0.0003 in - 0.0012 in) Crankshaft Bearing Clearance Axial...................................................................................................................0.100 mm - 0.202 mm (0.0039 in - 0.008 in) Crankshaft Bearing Out Of Round..................................................................... ......................................................................................0.03 mm (0.0012 in) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Engine - Procedure To Install Engine Oil Heater Engine Block Heater: Technical Service Bulletins Engine - Procedure To Install Engine Oil Heater INFORMATION Bulletin No.: 11-06-01-001A Date: March 08, 2011 Subject: Procedure for Installation of an Engine Oil Heater Models: 2011 Chevrolet Cruze Supercede: This bulletin is being revised to add information for the 1.8L (RPO LUW) Engine. Please discard Corporate Bulletin Number 11-06-01-001 (Section 06 - Engine/Propulsion System). If a customer is in an area of extreme cold, where the temperature falls below -30°C (-22°F), it is recommended that they install an engine oil heater. This will provide easier cold starting and better protection for the engine at extremely low temperatures. Important Please inform the customer that the engine oil heater should be plugged in a minimum of three hours prior to starting the vehicle. Using the parts listed below, follow the applicable procedure to install the engine oil heater. 1.4L Engine (RPO LUJ) 1. Raise and support the vehicle. 2. Loosely install the heater bracket to the engine block using provided bolt. 3. Clean the oil pan surface and wipe dry with a clean lint-free towel prior to installing the heater. 4. Apply the paste to the back side of the heater. Evenly coat the entire surface. 5. Install the heater to the oil pan and retain using the bracket. Tighten Tighten the bolt to 40Nm (30 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Engine - Procedure To Install Engine Oil Heater > Page 1528 6. Connect the power cord to the heater and secure using lock. 7. Install the power cord bracket, P/N 96312504, to the intermediate shaft bracket (1) using the existing bolt. 8. Route the power cord up along the back side of the intermediate shaft and secure the push in retainer (2) to the installed bracket. 9. Lower the vehicle. 10. Secure the power cord clip (1) to the heater hose. 11. Secure the power cord clip (1) to the existing engine harness. 12. Route the power cord along the strut tower and secure the push in retainer (2) into upper hole on strut tower. 13. Route the power cord along the front side of the strut tower and secure the clip (1) to the A/C line. For non-A/C vehicles, secure using the stud Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Engine - Procedure To Install Engine Oil Heater > Page 1529 clip. 14. Route the power cord along the side of the air cleaner assembly between the fender and secure the clip (1) to the forward lamp harness (just to the left of the headlamp). 15. Loop the power cord and route back along the side of the air cleaner and secure using clips. Tuck the electrical plug between the air cleaner assembly and the strut tower. 1.8L Engine (RPO LUW) 1. Raise and support the vehicle. 2. Loosely install the heater bracket to the engine block using provided bolt. 3. Clean the oil pan surface and wipe dry with a clean lint-free towel prior to installing the heater. 4. Apply the paste to the backside of the heater. Evenly coat the entire surface. 5. Install the heater to the oil pan and retain using the bracket. Tighten Tighten the bolt to 40Nm(30 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Engine - Procedure To Install Engine Oil Heater > Page 1530 6. Connect the power cord to the heater and install the safety lock (1) onto the heater connection. 7. Loop the power cord and secure the clip (2) to the heater element line. 8. Route the power cord up between the axle shaft and the engine and secure the clip (1) to the existing engine harness near the backside of the generator. 9. Lower the vehicle. 10. Secure the power cord clip (1) to the throttle body vacuum hose. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Engine - Procedure To Install Engine Oil Heater > Page 1531 11. Route the power cord up along the strut tower and secure the push in retainer (1) into upper hole on strut tower. 12. Route the power cord along the front side of the strut tower and secure the clip (2) to the A/C line. For non-A/C vehicles, secure using the stud clip. 13. Route the power cord along the side of the air cleaner assembly between the fender and secure the clip (1) to the forward lamp harness (just to the left of the headlamp). 14. Loop the power cord and route back along the side of the air cleaner and secure using clips. Tuck the electrical plug between the air cleaner assembly and the strut tower. Parts Information (1.4L Engine RPO LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Engine - Procedure To Install Engine Oil Heater > Page 1532 * To Order: Contact Rubberworks by email @ [email protected], Fax to 519-582-1011 or by phone 519-582-0555 between 9 am and 4:30 pm EST Monday to Friday. ** It is estimated that a 90 ml tube will service seven vehicles. Please put unused material on the shelf for future use. Parts Information (1.8L Engine RPO LUW) * To Order: Contact Rubberworks by email @ [email protected], Fax to 519-582-1011 or by phone 519-582-0555 between 9 am and 4:30 pm EST Monday to Friday ** It is estimated that a 90 ml tube will service seven vehicles. Please put unused material on the shelf for future use. Warranty Information Please advise the customer that the engine oil heater can be purchased. Installation and/or cost of the heater will not be covered under the vehicle's warranty. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Balancer Bolt.....................................................................................................................................150 Nm + 45° + 15° (111 lb ft + 45° + 15°) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1536 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Balancer Replacement Special Tools * EN-470-B - Angular Torque Wrench * EN-956-1 - Extension * EN-49979 - Crankshaft Shock Mount Retainer For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove front compartment splash shield right side. Refer to Front Compartment Splash Shield Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Splash Shield Replacement). 3. Fix the drive belt tensioner, remove the drive belt from crankshaft balancer and lay aside. Refer to Drive Belt Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 4. Place collecting basin underneath. 5. Install EN-49979 - crankshaft shock mount retainer to EN-956-1 - extension. 6. Loosen the crankshaft balancer bolt (4) while fixing the crankshaft balancer (3) with EN-49979 crankshaft shock mount retainer (1) and EN-956-1 - extension (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1537 7. Remove the crankshaft balancer bolt (2). 8. Remove the crankshaft balancer (1). Installation Procedure Note: The crankshaft balancer flange must fit to the hexagon of the oil pump rotor (2) and to the two-flat of the crankshaft (1). 1. Install the crankshaft balancer carefully by pressing into position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1538 2. Measure the distance (a) between the crankshaft balancer (2) and the mark on the engine front cover (1). The distance (a) should be 5.5 mm (0.21654 in). Note: Never re-use the crankshaft balancer bolt. 3. Install a NEW crankshaft balancer bolt. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the crankshaft balancer bolt (4) to 150 Nm (111 lb ft) while fixing the crankshaft balancer (3) with EN-49979 - crankshaft shock mount retainer (1) and EN-956-1 - extension (2). Use EN-470-B - wrench. 5. Tighten the crankshaft balancer bolt to an additional 60° while fixing the crankshaft balancer (3) with EN-49979 - crankshaft shock mount retainer (1) and EN-956-1 - extension (2). 6. Install the drive belt to the crankshaft balancer and remove the fixing pin. Refer to Drive Belt Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 7. Install the front compartment splash shield right side. Refer to Front Compartment Splash Shield Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Splash Shield Replacement). 8. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1539 9. Check and correct engine oil level. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair Piston: Service and Repair Piston, Connecting Rod, and Bearing Replacement Special Tools EN-470-B - Angular Torque Wrench For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Open the hood. 2. Remove the cylinder head. Refer to Cylinder Head Replacement (1.4L LUH and LUJ) (See: Cylinder Head Assembly/Service and Repair). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Remove the oil pan. Refer to Oil Pan Replacement (1.4L LUH and LUJ) (See: Engine Lubrication/Oil Pan/Service and Repair). Note: Mark the installation position of the connecting rod bearing caps. The connecting rod bearings and bearing caps must not be interchanged with other connecting rods. 5. Remove the 4 connecting rod bearing cap bolts (1) of cylinder 2 and 3. 6. Remove the 2 connecting rod bearing caps (2) and the 2 connecting rod bearings of cylinder 2 and 3. 7. Rotate the crankshaft 180°. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Page 1543 8. Remove the 4 connecting rod bearing cap bolts (1) of cylinder 1 and 4. 9. Remove the 2 connecting rod bearing caps (2) and the 2 connecting rod bearings of cylinder 1 and 4. 10. Remove the 4 pistons (1) and connecting rods (2) and the 4 upper connecting rod bearings (3) from the cylinder block. Installation Procedure 1. For cleaning and inspection procedure, refer to Piston, Connecting Rod, and Bearing Cleaning and Inspection (1.4L LUH and LUJ) (See: Service and Repair/Overhaul/46. Piston, Connecting Rod, and Bearing Cleaning and Inspection). 2. Assemble the NEW piston and connecting rod. Refer to Piston and Connecting Rod Assemble (1.4L LUH and LUJ) (See: Service and Repair/Overhaul/47. Piston and Connecting Rod Assemble). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Page 1544 3. Adjust the piston ring joints as followed: 1. Upper compression ring (1) 2. Lower compression ring (4) 3. Oilring (2) or (3) 4. Oilring spacer (5) 4. The arrow (1) on the piston head must point to the timing side. 5. The markings on the connecting rods (2) must point to the transmission side. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Page 1545 6. Lubricate the piston rings, piston, inner cylinder bore surface and a piston ring compressor with clean engine oil. 7. Install the piston ring compressor in order to compress the piston rings. 8. Install the pistons (1) in compound with connecting rods (2) and upper connecting rod bearings (3) to the engine block and to the crankshaft. Note: The flarings (arrows) on the connecting rod bearing caps must point to the transmission side. The connecting rod bearing caps must be installed in their original position. 9. Install the 2 connecting rod bearings and the 2 connecting rod bearing caps (2) of cylinder 1 and 4. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 10. Install the 4 connecting rod bearing cap bolts (1) and tighten in the following sequence: 1. Tighten the connecting rod bearing cap bolts to 25 Nm (18 lb ft). 2. Tighten the connecting rod bearing cap bolts an additional 25°. Use EN-470-B - wrench. 11. Rotate the crankshaft 180°. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Page 1546 Note: The flarings (arrows) on the connecting rod bearing caps must point to the transmission side. The connecting rod bearing caps must be installed in their original position. 12. Install the 2 connecting rod bearings and the 2 connecting rod bearing caps (2) of cylinder 3 and 2. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 13. Install the 4 connecting rod bearing cap bolts (1) and tighten in the following sequence: 1. Tighten the connecting rod bearing cap bolts to 25 Nm (18 lb ft). 2. Tighten the connecting rod bearing cap bolts an additional 45°. Use EN-470-B - wrench. 14. Install the oil pan Refer to Oil Pan Replacement (1.4L LUH and LUJ) (See: Engine Lubrication/Oil Pan/Service and Repair). 15. Lower the vehicle. 16. Install the cylinder head. Refer to Cylinder Head Replacement (1.4L LUH and LUJ) (See: Cylinder Head Assembly/Service and Repair). 17. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Special Tools EN-34730-91 - Pressure Tester For equivalent regional tools, refer to Special Tools (See: Powertrain Management/Computers and Control Systems/Tools and Equipment). Warning Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. Warning Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Remove the fuel injector rail cap (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Page 1551 2. Relieve the fuel pressure. Use EN-34730-91 - pressure tester (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair Valve Cover: Service and Repair Camshaft Cover Replacement (1.4L LUH and LUJ) Removal Procedure 1. Open the hood. 2. Remove ignition coil. Refer to Ignition Coil Replacement (See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair). 3. Remove the positive crankcase ventilation pipe from camshaft cover. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (See: Powertrain Management/Emission Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair). 4. Remove engine control module wiring harness (1) from camshaft cover. * Disconnect intake camshaft position sensor wiring harness plug (7). * Disconnect intake camshaft position actuator solenoid valve wiring harness plug (6). * Disconnect exhaust camshaft position sensor wiring harness plug (4). * Disconnect exhaust camshaft position actuator solenoid valve wiring harness plug (5). * Disconnect engine coolant temperature sensor wiring harness plug (3). * Disconnect engine oil pressure indicator switch wiring harness plug (2). * Unclip engine control module wiring harness plug from camshaft cover and lay aside. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Page 1555 5. Remove the oil level indicator (1). 6. Remove the 15 camshaft cover bolts (1). 7. Remove the camshaft cover (2) and the camshaft cover gasket (3). Installation Procedure 1. Clean the sealing surfaces. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Page 1556 Note: The thickness of the sealing bead should be 2 mm (0.0787 in). 2. Apply sealing compound to areas (1) and (2). Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers). Note: The installation procedure should not take longer than 10 minutes. 3. Install the camshaft cover (2) and a NEW gasket (3). 4. Install the 15 camshaft cover bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Page 1557 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the 15 camshaft cover bolts in a sequence as shown to 8 Nm (71 lb in). 6. Install engine control module wiring harness (1) to camshaft cover. * Clip engine control module wiring harness plug to camshaft cover. * Connect intake camshaft position sensor wiring harness plug (7). * Connect intake camshaft position actuator solenoid valve wiring harness plug (6). * Connect exhaust camshaft position sensor wiring harness plug (4). * Connect exhaust camshaft position actuator solenoid valve wiring harness plug (5). * Connect engine coolant temperature sensor wiring harness plug (3). * Connect engine oil pressure indicator switch wiring harness plug (2). 7. Install ignition coil. Refer to Ignition Coil Replacement (See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair). 8. Install the positive crankcase ventilation pipe to camshaft cover. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (See: Powertrain Management/Emission Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair). 9. Check and correct engine oil level. 10. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair Valve Spring: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement Special Tools * EN-958 - Installer * EN-6086 - Basic Kit, Spring and Wedge Replacer * EN-840 - Pliers / Remover * EN-952 - Fixing Pin For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the front compartment splash shield right side. Refer to Front Compartment Splash Shield Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Splash Shield Replacement). 3. Lower the vehicle. 4. Remove the hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm Replacement (See: Camshaft, Lifters and Push Rods/Lifter / Lash Adjuster/Service and Repair/Hydraulic Valve Lash Adjuster Arm Replacement). 5. Remove the spark plugs. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). Note: Wheels must contact the ground. 6. Shift to 5. gear (MT) or park position (AT) and apply the park brake. 7. Adjust the engine to TDC of cylinder 1 and fix the crankshaft. Refer to Camshaft Timing Chain Adjustment (See: Service and Repair/Overhaul/4. Camshaft Timing Chain Adjustment). 8. Mark the crankshaft balancer 180° opposed to the cylinder 1 TDC marking. Intake Valve Stem Oil Seal Removal Cylinder 1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1561 1. Prepare the 2 EN-6086-6 - supports (1) for the installation by tightening the support head in a centered position to the rail with the bolt (2). 2. Install the EN-6086-5 - mounting shaft (3) along with the 2 EN-6086-6 - supports (4) and the EN-6086-8 - handle to the cylinder head. Note: The demounting piece must point to the intake side. 3. Install the EN-6086-7 - lever (2) along with the EN-6086-11 - demounting piece (1) to the mounting shaft. 4. Position the mounting shaft centered above the spark plug bores and tighten the 4 fasteners (6). 5. Install the EN-6086-15 - pneumatic adapter (5) to the spark plug screw bore of cylinder 1. 6. Apply air pressure to cylinder 1. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1562 7. Remove the valve keys, valve spring retainers and the valve springs of the intake valves of cylinder 1, using the following procedure: Caution: The demounting piece part of EN-6086 Basic Kit, Spring and Wedge Replacer must be applied parallel to the valve retainers in order to prevent damage to the tools or the valve train components. If demounting piece is not applied parallel it could cause damage to the valve stem keys or the valve retainers. 1. Apply tension to the valve springs, using the EN-6086-7 - lever (1) and the EN-6086-11 demounting piece (2) until the valve keys are discharged from spring load and remove the valve keys. 2. Release tension from the valve springs and remove the valve spring retainers and the valve springs. 8. Remove the intake valve stem oil seals (2) of cylinder 1, using the EN-840 - pliers (1). Intake Valve Stem Oil Seal Installation Cylinder 1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1563 Note: Lubricate the NEW intake valve stem oil seals with clean engine oil. 1. Install the NEW intake valve stem oil seals of cylinder 1, using the EN-958 - installer (1). 2. Prepare the EN-6086-200-1 - mounting piece for the valve key installation. The mounting piece must be assembled in the following order: 1. Support (6) 2. Bushing (5) 3. Spring (4) 4. EN-6086-200-10 - plunger (3) 5. Screw Connection (2) 6. Lever Adapter (1) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1564 3. Install the valve keys (1) to the mounting piece (2) and fix them with the bushing. 4. Install the intake valve springs, the intake valve spring retainers and the intake valve keys, using the following procedure: 1. Replace the EN-6086-11 - demounting piece with the assembled EN-6086-200-1 - mounting piece (1). 2. Install the intake valve springs and the intake valve spring retainers to the cylinder head. Caution: The demounting piece part of EN-6086 Basic Kit, Spring and Wedge Replacer must be applied parallel to the valve retainers in order to prevent damage to the tools or the valve train components. If demounting piece is not applied parallel it could cause damage to the valve stem keys or the valve retainers. Note: The cone side of the valve keys must point to the valve stem. 3. Push down the mounting piece (1) using the lever (2) until the valve keys are hearable engaged. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1565 4. Inspect the intake valve keys (1) for proper seat. Exhaust Valve Stem Oil Seal Removal Cylinder 1 Remove the exhaust valve stem oil seals of cylinder 1: 1. Transfer the EN-6086-7 - lever to the exhaust side of cylinder 1. 2. Replace the EN-6086-200-1 mounting piece with the EN-6086-11 - demounting piece. 3. Remove the exhaust valve keys, exhaust valve spring retainers, exhaust valve springs and the exhaust valve stem oil seals as described above. Exhaust Valve Stem Oil Seal Installation Cylinder 1 1. Replace the EN-6086-11 - demounting piece with the assembled EN-6086-200-1 - mounting piece (1). 2. Install the exhaust valve keys, exhaust valve spring retainers, exhaust valve springs and the exhaust valve stem oil seals of cylinder 1 as described above. Intake Valve Stem Oil Seal Removal Cylinder 4 1. Release the air pressure from cylinder 1. 2. Transfer the EN-6086-15 - pneumatic adapter from cylinder 1 to the spark plug bore of cylinder 4. 3. Apply air pressure to cylinder 4. 4. Transfer the EN-6086-7 - lever to the intake side of cylinder 4. 5. Replace the EN-6086-200-1 - mounting piece with the EN-6086-11 - demounting piece. 6. Remove the intake valve keys, intake valve spring retainers, intake valve springs and the intake valve stem oil seals of cylinder 4 as described above. Intake Valve Stem Oil Seal Installation Cylinder 4 1. Replace the EN-6086-11 - demounting piece with the assembled EN-6086-200-1 - mounting piece. 2. Install the intake valve keys, intake valve spring retainers, intake valve springs and the intake valve stem oil seals of cylinder 4 as described above. Exhaust Valve Stem Oil Seal Removal And Installation Cylinder 4 Replace the exhaust valve keys, exhaust valve spring retainers, exhaust valve springs and the exhaust valve stem oil seals of cylinder 4 as described above. Intake Valve Stem Oil Seal Removal Cylinder 2 1. Release the air pressure from cylinder 4. 2. Raise the vehicle. 3. Remove the EN-952 - fixing pin from the crankshaft. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1566 4. Rotate the crankshaft balancer in engine rotation direction until the 180° opposite marking (2) aligns with the marking (1) on the engine front cover. 5. Lower the vehicle. Note: Wheels must contact the ground. 6. Block the engine by shifting the 5. gear (MT) or park position (AT) and applying the park brake. 7. Transfer the EN-6086-15 - pneumatic adapter from cylinder 4 to the spark plug bore of cylinder 2. 8. Apply air pressure to cylinder 2. 9. Transfer the EN-6086-7 - lever to the intake side of cylinder 2. 10. Replace the EN-6086-200-1 - mounting piece with the EN-6086-11 - demounting piece. 11. Remove the intake valve keys, intake valve spring retainers, intake valve springs and the intake valve stem oil seals of cylinder 2 as described above. Intake Valve Stem Oil Seal Installation Cylinder 2 1. Transfer the EN-6086-7 - lever to the exhaust side of cylinder 2. 2. Replace the EN-6086-11 demounting piece with the assembled EN-6086-200-1 - mounting piece (1). 3. Install the intake valve keys, intake valve spring retainers, intake valve springs and the intake valve stem oil seals of cylinder 2 as described above. Exhaust Valve Stem Oil Seal Removal And Installation Cylinder 2 Replace the exhaust valve keys, exhaust valve spring retainers, exhaust valve springs and the exhaust valve stem oil seals of cylinder 2 as described above. Intake Valve Stem Oil Seal Removal Cylinder 3 1. Release the air pressure from cylinder 2. 2. Transfer the EN-6086-15 - pneumatic adapter from cylinder 2 to the spark plug bore of cylinder 3. 3. Apply air pressure to cylinder 3. 4. Transfer the EN-6086-7 - lever to the intake side of cylinder 3. 5. Replace the EN-6086-200-1 - mounting piece with the EN-6086-11 - demounting piece. 6. Remove the intake valve keys, intake valve spring retainers, intake valve springs and the intake valve stem oil seals of cylinder 3 as described above. Intake Valve Stem Oil Seal Installation Cylinder 3 1. Transfer the EN-6086-7 - lever to the exhaust side of cylinder 3. 2. Replace the EN-6086-11 demounting piece with the assembled EN-6086-200-1 - mounting piece. 3. Install the intake valve keys, intake valve spring retainers, intake valve springs and the intake valve stem oil seals of cylinder 3 as described above. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1567 Exhaust Valve Stem Oil Seal Removal And Installation Cylinder 3 Replace the exhaust valve keys, exhaust valve spring retainers, exhaust valve springs and the exhaust valve stem oil seals of cylinder 3 as described above. Installation Procedure 1. Release air pressure from cylinder 3. 2. Remove the EN-6086-15 - pneumatic adapter. 3. Remove all parts of EN-6086 - spring and wedge replacer. 4. Shift to neutral gear and release the park brake. 5. Adjust the engine to TDC of cylinder 1 and fix the crankshaft with EN-952 - fixing pin. 6. Install the spark plugs. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). 7. Install the hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm Replacement (See: Camshaft, Lifters and Push Rods/Lifter / Lash Adjuster/Service and Repair/Hydraulic Valve Lash Adjuster Arm Replacement). 8. Raise the vehicle. 9. Remove the EN-952 - fixing pin and install the crankshaft bearing cap tie plate hole plug. Refer to Camshaft Timing Chain Adjustment (See: Service and Repair/Overhaul/4. Camshaft Timing Chain Adjustment). 10. Install the front compartment splash shield right side. Refer to Front Compartment Splash Shield Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Splash Shield Replacement). 11. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Drive Belt Routing Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 1572 Drive Belt: Service Precautions Belt Dressing Caution Caution: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt: Testing and Inspection Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt Chirping, Squeal, and Whine Diagnosis Diagnostic Aids * A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It may be necessary to spray a small amount of water on the drive belts in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution. * If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. * A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or suspension component. Other items of the vehicle may also cause the noise. * The drive belts will not cause a whine noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belts one at a time and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 15. This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 16. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 17. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. 19. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1575 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1576 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1577 Drive Belt: Testing and Inspection Drive Belt Rumbling and Vibration Diagnosis Drive Belt Rumbling and Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused by, but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belts are installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belts the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspecting the drive belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation can be recognized at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt, nut, spacer, or washer was installed. 11. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known good water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1578 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1579 Drive Belt: Testing and Inspection Drive Belt Falls Off and Excessive Wear Diagnosis Drive Belt Falls Off and Excessive Wear Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears or sections of ribs missing. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut , spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. 13. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulley. 14. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 15. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1580 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 1581 Drive Belt: Service and Repair Drive Belt Replacement Special Tools * EN-955-2 - Locking Pin * EN-48488 - Holding Wrench For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Open the hood. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the right front compartment splash shield. Refer to Front Compartment Splash Shield Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Splash Shield Replacement). 4. Install EN-48488 - holding wrench (2) to the drive belt tensioner (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 1582 5. Move the drive belt tensioner clockwise until the drive belt tensioner can be fixed with EN-955-2 locking pin (1). 6. Remove the EN-48488 - holding wrench. 7. Lower the vehicle. 8. Remove the right engine mount. Refer to Engine Mount Replacement - Right Side (See: Engine Mount/Service and Repair/Removal and Replacement/Engine Mount Replacement - Right Side). 9. Remove the drive belt. Installation Procedure 1. Install the drive belt. 2. Install the right engine mount. Refer to Engine Mount Replacement Right Side (See: Engine Mount/Service and Repair/Removal and Replacement/Engine Mount Replacement - Right Side). 3. Raise the vehicle. 4. Install the EN-48488 - holding wrench (2) to the drive belt tensioner (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 1583 5. Move the drive belt tensioner clockwise until EN-955-2 - locking pin (1) can be removed. 6. Allow the tensioner to slide back slowly. 7. Remove the EN-48488 - holding wrench. 8. Install the front compartment splash shield right side. Refer to Front Compartment Splash Shield Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Splash Shield Replacement). 9. Lower the vehicle. 10. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection Drive Belt Tensioner: Testing and Inspection Drive Belt Tensioner Diagnosis Special Tools EN-48488 - Holding Wrench For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). 1. Diagnosis consists of a function check on the automatic belt tensioner and a visual check on the belt and the components linked to the belt. 2. Install the EN-48488 - wrench (2) to the drive belt tensioner pulley bolt (1). 3. Apply tension to the drive belt tensioner spring (3) by moving the drive belt tensioner pulley clockwise. 4. Allow the drive belt tensioner to slide back slowly and thereby inspect the drive belt tensioner mechanism for practicability. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection > Page 1587 Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement * EN-955-2 - Locking Pin * EN-956 - Holding Wrench For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Open the hood. 2. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side (See: Engine Mount/Service and Repair/Removal and Replacement/Engine Mount Bracket Replacement - Right Side). Note: Engine mount bracket is removed. 3. Install the EN-956 - holding wrench (2) to the drive belt tensioner (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection > Page 1588 4. Move the drive belt tensioner clockwise until the drive belt tensioner can be fixed with EN-955-2 locking pin (1). 5. Remove the EN-956 - holding wrench. 6. Remove the drive belt. 7. Repeat step 3 and 4 in order to remove the EN-955-2 - locking pin the from drive belt tensioner. 8. Remove the upper drive belt tensioner bolt (2). 9. Remove the lower drive belt tensioner bolt (3). 10. Remove the drive belt tensioner (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection > Page 1589 1. Install the drive belt tensioner (1). 2. Install the lower drive belt tensioner bolt (3). 3. Install the upper drive belt tensioner bolt (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the lower drive belt tensioner bolt to 22 Nm (16 lb ft). 5. Tighten the upper drive belt tensioner bolt to 55 Nm (41 lb ft). Note: Engine mount bracket is removed. 6. Install the EN-956 - holding wrench (2) to drive belt tensioner (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection > Page 1590 7. Move the drive belt tensioner clockwise until the drive belt tensioner can be fixed with EN-955-2 locking pin (1). 8. Install the drive belt. 9. Move the drive belt tensioner clockwise until EN-955-2 locking pin can be removed. 10. Allow the tensioner to slide back slowly. 11. Remove the EN-956 - holding wrench. 12. Install the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side (See: Engine Mount/Service and Repair/Removal and Replacement/Engine Mount Bracket Replacement - Right Side). 13. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Testing and Inspection Engine Mount: Testing and Inspection Engine Mount Inspection 1. Install the engine support fixture. Refer to Engine Support Fixture (See: Service and Repair/Overhaul/1. Engine Support Fixture). 2. Observe the engine mount while raising the engine. Raising the engine removes the weight from the engine mount and creates slight tension on the rubber. 3. Replace the engine mount if the engine mount exhibits any of the following conditions: * The hard rubber is covered with heat check cracks. * The rubber is separated from the metal plate of the engine mount. * The rubber is split through the center of the engine mount. 4. For engine mount replacement, refer to Engine Mount Replacement - Right Side (See: Service and Repair/Removal and Replacement/Engine Mount Replacement - Right Side). 5. For rear transmission mount replacement, refer to: * Automatic transmission, refer to Transmission Rear Mount Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Transmission Mount/Service and Repair/Transmission Rear Mount Replacement). * Manual transmission, refer to Transmission Rear Mount Replacement (See: Transmission and Drivetrain/Manual Transmission/Transaxle/Transmission Mount/Service and Repair/Transmission Rear Mount Replacement). 6. For left transmission mount replacement, refer to: * Automatic transmission, refer to Transmission Mount Replacement - Left Side (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Transmission Mount/Service and Repair/Transmission Mount Replacement - Left Side). * Manual transmission, refer to Transmission Mount Bracket Replacement - Left Side (See: Transmission and Drivetrain/Manual Transmission/Transaxle/Transmission Mount/Service and Repair/Transmission Mount Bracket Replacement - Left Side). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures Engine Mount: Procedures Powertrain Mount Balancing Powertrain Mount Balancing Note: Follow the balance procedure steps listed below when no starting point has been established such as in a collision repair. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Loosen the front transaxle mount through bolt (1) until it is finger tight. 3. Loosen the rear transaxle mount (1) through bolt until it is finger tight. 4. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1596 5. Position two floor jacks with wood blocks under the engine and transaxle in order to support the powertrain assembly. 6. Loosen the transaxle adapter to transaxle bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1597 7. Loosen the engine mount (1) to bracket bolts (2). 8. Lower the floor jacks in order to allow a 1/4 inch (6 mm) gap between the upper engine mount and engine mount bracket, and also between the transmission and left transmission mount. 9. Check that the front and rear mounts are centered (1) in the mount brackets, adjust if necessary. 10. Tighten the left hand (transaxle side) mount bolts, starting with the bolt nearest to the center of the mount. See the appropriate transmission mount replacement procedure for the fastener tightening specifications. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1598 11. Tighten the right hand (engine side) mount bolts (1), starting with the bolt nearest to the center of the mount. See the appropriate engine mount replacement procedure for the fastener tightening specifications. 12. Remove the floor jacks from under the oil pan and transmission. 13. Raise the vehicle. 14. Shake the powertrain from front to rear and allow the powertrain to settle. Note: It is essential that the lower mount through bolts should be as close to centered as possible in the oversized mount insert holes before tightening to specification. 15. Tighten the rear transaxle mount through bolt (1). See the appropriate transmission mount replacement procedure for the fastener tightening specifications. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1599 16. Tighten the front transaxle mount through bolt (1). See the appropriate transmission mount replacement procedure for the fastener tightening specifications. 17. Lower the vehicle. Powertrain Mount Balancing - Lower Powertrain Mount Balancing - Lower Note: Follow the balance procedure steps listed below when front or rear mounts through bolts are loosened or removed during a repair procedure. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Loosen the front transaxle mount through bolt (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1600 3. Loosen the rear transaxle mount through bolt (1). 4. Shake the powertrain from front to rear and allow the powertrain to settle. Note: It is essential that the through bolts are as close to centered as possible in the oversized mount insert holes before tightening to specification. 5. Tighten the rear transaxle mount through bolt (1). See the appropriate transmission mount replacement procedure for the fastener tightening specifications. 6. Tighten the front transaxle mount through bolt (1). See the appropriate transmission mount replacement procedure for the fastener tightening specifications. 7. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1601 Engine Mount: Removal and Replacement Engine Mount Replacement - Right Side Engine Mount Replacement - Right Side Removal Procedure 1. Open the hood. 2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.4L LUH and LUJ) (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 3. Install an engine lifter (1) to the right engine lift bracket and apply tension to the engine lifter chain in order to support the engine. 4. Remove the 3 engine mount to engine mount bracket bolts (3) and the 3 washers (4). 5. Remove the 2 engine mount to body bolts (2) and the engine mount nut (1). 6. Remove the engine mount (5). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1602 Installation Procedure 1. Install the engine mount (5). 2. Install the 2 engine mount to body bolts (2). 3. Install the engine mount nut (1). 4. Install the 3 engine mount to engine mount bracket bolts (3) and the 3 washers (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the 2 engine mount to body bolts (2) and the engine mount nut (1) to 55 Nm (41 lb ft). 6. Tighten the 3 engine mount to engine mount bracket bolts (3) to 50 Nm (37 lb ft). 7. Remove the engine lifter from right engine lift bracket. 8. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.4L LUH and LUJ) (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 9. Close the hood. Engine Mount Bracket Replacement - Right Side Engine Mount Bracket Replacement - Right Side Removal Procedure 1. Open the hood. 2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.4L LUH and LUJ) (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 3. Remove the engine mount. Refer to Engine Mount Replacement - Right Side (See: Engine Mount Replacement - Right Side). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1603 4. Remove the 3 engine mount bracket bolts (1). 5. Remove the engine mount bracket (2). Installation Procedure 1. Install the engine mount bracket (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 engine mount bracket bolts (1) and tighten to 62 Nm (46 lb ft). 3. Install the engine mount. Refer to Engine Mount Replacement - Right Side (See: Engine Mount Replacement - Right Side). 4. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.4L LUH and LUJ) (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 5. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications The oil pressure at idle speed should be 150 kpa (22 psi) The oil pressure between 3000 - 3500 rpm should be 380 - 650 kpa (55 - 94 psi) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 1608 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing (1.4L LUH and LUJ) Special Tools * EN-498-B - Oil Pressure Gauge * EN-498-3 - Adapter For equivalent regional tools, refer to Special Tools (See: Tools and Equipment) Removal Procedure 1. Disconnect the oil pressure indicator switch wiring harness plug. 2. Remove the oil pressure indicator switch (1) and the oil pressure indicator switch seal ring (2). Measuring Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 1609 1. Install EN-498-B - gauge (1) along with EN-498-3 - adapter (2). 2. Start Engine. Note: The oil temperature should be between 80°C and 100°C. 3. Measure the oil pressure: * The oil pressure at idle speed should be 150kpa (22 psi). * The oil pressure between 3000 - 3500 rpm should be 380 - 650 kpa (55 - 94 psi). 4. Stop engine. 5. If the engine oil pressure is below specifications, inspect the engine for 1 or more of the following conditions: * Oil pump worn or dirty. Refer to Oil Pump Replacement (See: Oil Pump/Service and Repair) and Engine Front Cover and Oil Pump Cleaning and Inspection (See: Service and Repair/Overhaul/52. Engine Front Cover and Oil Pump Cleaning and Inspection). * Oil suction gallery clogged or dirty. Refer to Oil Pan Cleaning and Inspection (See: Service and Repair/Overhaul/59. Oil Pan Cleaning and Inspection) * Cracked, porous, or restricted oil galleries. * Oil pressure relief valve malfunction. 6. Remove EN-498-B - gauge and EN-498-3 - adapter. Installation Procedure 1. Install the oil pressure indicator switch and a NEW oil pressure indicator switch seal ring. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the oil pressure indicator switch to 20 Nm (15 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1614 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1615 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ ............................................. 4.25 quarts (4.0 liters) IMPORTANT: Oil filter should be changed at every oil change. NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1618 Engine Oil: Fluid Type Specifications Selecting the Right Engine Oil Selecting the right engine oil depends on both the proper oil specification and viscosity grade: Specification Use and ask for engine oils with the dexosTM certification mark. Oils meeting the requirements of the vehicle should have the dexos certification mark on the container. This certification mark indicates that the oil has been approved to the dexos specification. This vehicle was filled at the factory with dexos-approved engine oil. Notice: Use only engine oil that is approved to the dexos specification or an equivalent engine oil of the appropriate viscosity grade. Engine oils approved to the dexos specification will show the dexos symbol on the container. Failure to use the recommended engine oil or equivalent can result in engine damage not covered by the vehicle warranty. If you are unsure whether the oil is approved to the dexos specification, ask your service provider. Use of Substitute Engine Oils if dexos is unavailable: In the event that dexos-approved engine oil is not available at an oil change or for maintaining proper oil level, you may use substitute engine oil displaying the API Starburst symbol and of SAE 5W-30 viscosity grade. Use of oils that do not meet the dexos specification, however, may result in reduced performance under certain circumstances. Viscosity Grade SAE 5W-30 is the best viscosity grade for the vehicle. Do not use other viscosity oils such as SAE 10W-30, 10W-40, or 20W-50. Cold Temperature Operation: In an area of extreme cold, where the temperature falls below -29°C (-20°F), an SAE 0W-30 oil should be used. An oil of this viscosity grade will provide easier cold starting for the engine at extremely low temperatures. When selecting an oil of the appropriate viscosity grade, be sure to always select an oil that meets the required specification, dexos. "Specification" earlier in this section for more information. Engine Oil Additives/Engine Oil Flushes Do not add anything to the oil. The recommended oils with the dexos specification and displaying the dexos certification mark are all that is needed for good performance and engine protection. Engine oil system flushes are not recommended and could cause engine damage not covered by the vehicle warranty. What to Do with Used Oil Used engine oil contains certain elements that can be unhealthy for your skin and could even cause cancer. Do not let used oil stay on your skin for very long. Clean your skin and nails with soap and water, or a good hand cleaner. Wash or properly dispose of clothing or rags containing used engine oil. the manufacturer's warnings about the use and disposal of oil products. Used oil can be a threat to the environment. If you change your own oil, be sure to drain all the oil from the filter before disposal. Never dispose of oil by putting it in the trash or pouring it on the ground, into sewers, or into streams or bodies of water. Recycle it by taking it to a place that collects used oil. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1619 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Open hood. 2. Place a drain pan below the vehicle. 3. Remove the engine oil filter cap (2) in compound with the engine oil filter cap seal ring (3) and the oil filter element (1). 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the oil pan drain plug and allow the oil to drain into the drain pan. Installation Procedure 1. Clean the oil pan drain plug thread in the oil pan. 2. Install a NEW seal ring to the oil pan drain plug. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the oil pan drain plug and tighten to 14 Nm (124 lb in). 4. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1620 Note: Lubricate the NEW oil filter cap seal ring with engine oil. 5. Install the engine oil filter cap (2) in compound with a NEW engine oil filter cap seal ring (3) and a NEW oil filter element (1). Caution: Over torquing the oil filter cap may cause damage to the oil filter cap resulting in an oil leak. 6. Tighten the engine oil filter cap to 25 Nm (18 lb ft). Caution: Using engine oils of any viscosity other than those viscosities recommended could result in engine damage. Note: Do not overfill the engine with engine oil. 7. Fill in NEW engine oil. Refer to Engine Mechanical Specifications (See: Specifications/Service Limits & General Specifications) to find the specified viscosity and volume. 8. Start the engine and allow it to run until the oil pressure control indicator goes off. 9. Inspect the engine oil level. 10. Close hood. 11. Reset the service interval indicator. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Inlet Pipe Replacement Oil Cooler: Service and Repair Engine Oil Cooler Inlet Pipe Replacement Engine Oil Cooler Inlet Pipe Replacement (1.4L LUH, LUJ) Removal Procedure 1. Drain coolant fluid. Refer to Cooling System Draining and Filling (Static Fill) (See: Cooling System/Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Cooling System/Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). 2. Remove the warm up three way catalytic converter. Refer to Warm Up Three-Way Catalytic Converter Replacement (1.4L LUH and LUJ) (See: Exhaust System/Heat Shield/Service and Repair/Warm Up Three-Way Catalytic Converter Replacement). 3. Remove the engine oil cooler inlet hose from the engine oil cooler inlet pipe. Refer to Engine Oil Cooler Inlet Hose Replacement (1.4L LUH and LUJ) (See: Engine Oil Cooler Inlet Hose Replacement). 4. Remove the turbocharger coolant return pipe hose clamp (3). 5. Remove the turbocharger coolant return pipe hose (2) from the engine oil cooler inlet pipe. Note: Do not move the turbocharger coolant return pipe too much. An excessive moving of the turbocharger coolant return pipe could cause leakage. 6. Remove the turbocharger coolant return pipe bolt (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Inlet Pipe Replacement > Page 1625 7. Remove the engine oil cooler bolt (1). 8. Remove the engine oil cooler inlet pipe bolt (4). 9. Remove the engine oil cooler inlet pipe (2) and the seal ring (3). Installation Procedure 1. Install the engine oil cooler inlet pipe (2) in compound with a NEW seal ring (3). 2. Install the engine oil cooler bolt (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the engine oil cooler inlet pipe bolt (4) and tighten to 10 Nm (89 lb in). 4. Tighten the engine oil cooler bolt (1) to 20 Nm (15 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Inlet Pipe Replacement > Page 1626 5. Install the turbocharger coolant return pipe hose (2) to the engine oil cooler inlet pipe. 6. Install the turbocharger coolant return pipe hose clamp (3). 7. Install turbocharger coolant return pipe bolt (1) and tighten to 10 Nm (89 lb in). 8. Install the engine oil cooler inlet hose to the engine oil cooler inlet pipe. Refer to Engine Oil Cooler Inlet Hose Replacement (1.4L LUH and LUJ) (See: Engine Oil Cooler Inlet Hose Replacement). 9. Install the warm up three way catalytic converter. Refer to Warm Up Three-Way Catalytic Converter Replacement (1.4L LUH and LUJ) (See: Exhaust System/Heat Shield/Service and Repair/Warm Up Three-Way Catalytic Converter Replacement). 10. Fill up coolant fluid. Refer to Cooling System Draining and Filling (Static Fill) (See: Cooling System/Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Cooling System/Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Inlet Pipe Replacement > Page 1627 Oil Cooler: Service and Repair Engine Oil Cooler Replacement Engine Oil Cooler Replacement (1.4L LUH, LUJ) Removal Procedure 1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Drain engine coolant. Refer to Cooling System Draining and Filling (Static Fill) (See: Cooling System/Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Cooling System/Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)) 3. Remove the turbocharger oil feed pipe. Refer to Turbocharger Oil Feed Pipe Replacement (See: Oil Line/Service and Repair/Turbocharger Oil Feed Pipe Replacement). 4. Remove the warm up three way catalytic converter. Refer to Warm Up Three-Way Catalytic Converter Replacement (1.4L LUH and LUJ) (See: Exhaust System/Heat Shield/Service and Repair/Warm Up Three-Way Catalytic Converter Replacement). 5. Lower vehicle. 6. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (1.4L LUH and LUJ) (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 7. Remove the oil cooler outlet hose clamp (2). 8. Remove the oil cooler outlet hose (3) from the thermostat housing (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Inlet Pipe Replacement > Page 1628 9. Remove the turbocharger coolant return pipe bolt (1) from the oil cooler housing. 10. Remove the turbocharger coolant return pipe clamp (2). Note: Do not move the turbocharger coolant return pipe too much. An excessive moving of the turbocharger coolant return pipe could cause leakage. 11. Remove the turbocharger coolant return pipe (3) from the oil cooler inlet pipe. 12. Disconnect the oil pressure indicator switch wiring harness plug. 13. Remove the oil cooler inlet hose clamp (1) and remove the oil cooler inlet hose from the water outlet. 14. Remove the engine oil cooler bolt (5). 15. Remove the engine oil cooler inlet pipe bolt (4). 16. Remove the engine oil cooler inlet pipe (2) and the seal ring (3). 17. Raise vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Inlet Pipe Replacement > Page 1629 18. Remove the oil cooler outlet pipe bolt (1) from the engine block. 19. Remove the oil cooler outlet pipe (2) in compound with the oil cooler outlet hose. 20. Lower vehicle. 21. Remove the 2 oil cooler bolts (1). 22. Raise vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Inlet Pipe Replacement > Page 1630 23. Remove the oil cooler (1) in compound with the oil cooler gasket (2) and the seal ring (3). 24. Remove the oil pressure indicator switch from the oil cooler. Installation Procedure 1. Install the oil pressure indicator switch to the oil cooler. Use a NEW seal ring. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the oil pressure indicator switch to 20 Nm (15 lb ft). 3. Clean the sealing surfaces. 4. Install the oil cooler (1) in compound with a NEW oil cooler gasket (2) and a NEW seal ring (3). 5. Lower vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Inlet Pipe Replacement > Page 1631 6. Install the 2 oil cooler bolts (1) and hand tighten. 7. Install the engine oil cooler inlet pipe (2) in compound with a NEW seal ring (3). 8. Install the oil cooler inlet hose to the water outlet and install the oil cooler inlet hose clamp (1). 9. Install the engine oil cooler bolt (5). 10. Install the engine oil cooler inlet pipe bolt (4) and tighten to 10 Nm (89 lb in). 11. Tighten the 3 engine oil cooler bolts to 20 Nm (15 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Inlet Pipe Replacement > Page 1632 12. Install the turbocharger coolant return pipe (3) to the oil cooler inlet pipe. 13. Install the turbocharger coolant return pipe clamp (2). 14. Install turbocharger coolant return pipe bolt (1) and tighten to 10 Nm (89 lb in). 15. Connect the oil pressure indicator switch wiring harness plug. 16. Raise vehicle. 17. Install the oil cooler outlet pipe (2) in compound with the oil cooler outlet hose to the oil cooler. 18. Install the oil cooler outlet pipe bolt (1) to the engine block and tighten to 10 Nm (89 lb in). 19. Install the warm up three way catalytic converter. Refer to Warm Up Three-Way Catalytic Converter Replacement (1.4L LUH and LUJ) (See: Exhaust System/Heat Shield/Service and Repair/Warm Up Three-Way Catalytic Converter Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Inlet Pipe Replacement > Page 1633 20. Install the oil cooler outlet hose (3) to the thermostat housing (1). 21. Install the oil cooler outlet hose clamp (2). 22. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (1.4L LUH and LUJ) (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 23. Install the turbocharger oil feed pipe and the exhaust manifold heat shield. Refer to Turbocharger Oil Feed Pipe Replacement (See: Oil Line/Service and Repair/Turbocharger Oil Feed Pipe Replacement). 24. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 25. Fill engine coolant. Refer to Cooling System Draining and Filling (Static Fill) (See: Cooling System/Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Cooling System/Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Inlet Pipe Replacement > Page 1634 Oil Cooler: Service and Repair Engine Oil Cooler Inlet Hose Replacement Engine Oil Cooler Inlet Hose Replacement (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Inlet Pipe Replacement > Page 1635 Oil Cooler: Service and Repair Engine Oil Cooler Outlet Hose Replacement Engine Oil Cooler Outlet Hose Replacement (1.4L LUH and LUJ) Removal Procedure 1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection) 2. Drain engine coolant. Refer to Cooling System Draining and Filling (Static Fill) (See: Cooling System/Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Cooling System/Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)) 3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (1.4L LUH and LUJ) (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement) 4. Remove the oil cooler outlet hose clamp (2). 5. Remove the oil cooler outlet hose (3) from the thermostat housing (1). 6. Remove the warm up three way catalytic converter. Refer to Warm Up Three-Way Catalytic Converter Replacement (1.4L LUH and LUJ) (See: Exhaust System/Heat Shield/Service and Repair/Warm Up Three-Way Catalytic Converter Replacement) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Inlet Pipe Replacement > Page 1636 7. Remove the oil cooler outlet pipe bolt (1) from the engine block. 8. Remove the oil cooler outlet pipe (2) in compound with the oil cooler outlet hose. 9. Remove the oil cooler outlet hose clamp. 10. Remove the oil cooler outlet hose from the oil cooler outlet pipe. Installation Procedure 1. Install the oil cooler outlet hose to the oil cooler outlet pipe. 2. Install the oil cooler outlet hose clamp. 3. Install the oil cooler outlet pipe (2) in compound with the oil cooler outlet hose to the oil cooler. 4. Install the oil cooler outlet pipe bolt (1) to the engine block and tighten to 10 Nm (89 lb in). 5. Install the warm up three way catalytic converter. Refer to Warm Up Three-Way Catalytic Converter Replacement (1.4L LUH and LUJ) (See: Exhaust System/Heat Shield/Service and Repair/Warm Up Three-Way Catalytic Converter Replacement) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Inlet Pipe Replacement > Page 1637 6. Install the oil cooler outlet hose (3) to the thermostat housing (1). 7. Install the oil cooler outlet hose clamp (2). 8. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (1.4L LUH and LUJ) (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement) 9. Install the turbocharger oil feed pipe and the exhaust manifold heat shield. Refer to Turbocharger Oil Feed Pipe Replacement (See: Oil Line/Service and Repair/Turbocharger Oil Feed Pipe Replacement) 10. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection) 11. Fill engine coolant. Refer to Cooling System Draining and Filling (Static Fill) (See: Cooling System/Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Cooling System/Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Open hood. 2. Place a drain pan below the vehicle. 3. Remove the engine oil filter cap (2) in compound with the engine oil filter cap seal ring (3) and the oil filter element (1). 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the oil pan drain plug and allow the oil to drain into the drain pan. Installation Procedure 1. Clean the oil pan drain plug thread in the oil pan. 2. Install a NEW seal ring to the oil pan drain plug. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the oil pan drain plug and tighten to 14 Nm (124 lb in). 4. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Page 1641 Note: Lubricate the NEW oil filter cap seal ring with engine oil. 5. Install the engine oil filter cap (2) in compound with a NEW engine oil filter cap seal ring (3) and a NEW oil filter element (1). Caution: Over torquing the oil filter cap may cause damage to the oil filter cap resulting in an oil leak. 6. Tighten the engine oil filter cap to 25 Nm (18 lb ft). Caution: Using engine oils of any viscosity other than those viscosities recommended could result in engine damage. Note: Do not overfill the engine with engine oil. 7. Fill in NEW engine oil. Refer to Engine Mechanical Specifications (See: Specifications/Service Limits & General Specifications) to find the specified viscosity and volume. 8. Start the engine and allow it to run until the oil pressure control indicator goes off. 9. Inspect the engine oil level. 10. Close hood. 11. Reset the service interval indicator. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Turbocharger > Component Information > Service and Repair > Turbocharger Oil Feed Pipe Replacement Oil Line: Service and Repair Turbocharger Oil Feed Pipe Replacement Turbocharger Oil Feed Pipe Replacement Removal Procedure 1. Open the hood. 2. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (1.4L LUH and LUJ) (See: Exhaust System/Heat Shield/Service and Repair/Exhaust Manifold Heat Shield Replacement)Exhaust Manifold Heat Shield Replacement (1.6L LDE, LXV, 1.8L 2H0, and LUW) (See: Exhaust System/Heat Shield/Service and Repair/Exhaust Manifold Heat Shield Replacement). 4. Remove the turbocharger oil feed pipe bolt (5). 5. Remove the turbocharger oil feed pipe hollow screw (4) and the 2 seal rings (1) and (3). 6. Remove the turbocharger oil feed pipe (2) and the rubber seal ring. Installation Procedure 1. Clean the sealing surfaces. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Turbocharger > Component Information > Service and Repair > Turbocharger Oil Feed Pipe Replacement > Page 1646 2. Install the turbocharger oil feed pipe (2) along with a NEW rubber seal ring. 3. Install the turbocharger oil feed pipe hollow screw (4) and 2 NEW seal rings (1) and (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the turbocharger oil feed pipe bolt (5) and tighten to 10 Nm (89 lb in). 5. Tighten the turbocharger oil feed pipe hollow screw to 30 Nm (22 lb ft). 6. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (1.4L LUH and LUJ) (See: Exhaust System/Heat Shield/Service and Repair/Exhaust Manifold Heat Shield Replacement)Exhaust Manifold Heat Shield Replacement (1.6L LDE, LXV, 1.8L 2H0, and LUW) (See: Exhaust System/Heat Shield/Service and Repair/Exhaust Manifold Heat Shield Replacement). 7. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 8. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Turbocharger > Component Information > Service and Repair > Turbocharger Oil Feed Pipe Replacement > Page 1647 Oil Line: Service and Repair Turbocharger Oil Return Pipe Replacement Turbocharger Oil Return Pipe Replacement Removal procedure 1. Open the hood. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) Note: Simplified Graphic. DO NOT remove the warm up three way catalytic converter. 3. Remove the 2 turbocharger oil return pipe bolts (1). 4. Place a drain pan below the vehicle. 5. Release the turbocharger oil return pipe connector (4) and disconnect the turbocharger oil return pipe from the engine block. 6. Remove the turbocharger oil return pipe (2) and the gasket (3). Installation Procedure 1. Clean the sealing surfaces. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Turbocharger > Component Information > Service and Repair > Turbocharger Oil Feed Pipe Replacement > Page 1648 2. Install the turbocharger oil return pipe (2) in compound with a NEW gasket (3) and connect to the engine block. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 2 turbocharger oil return pipe bolts (1) and tighten to 8 Nm (71 lb in). 4. Lower the vehicle. 5. Check engine oil level. 6. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair Oil Pan: Service and Repair Oil Pan Replacement (1.4L LUH and LUJ) Special Tools EN-49980 - Guidance Pins For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Open the hood. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Drain engine oil. Refer to Engine Oil and Oil Filter Replacement (See: Engine Oil/Service and Repair). 4. Remove the catalytic converter. Refer to Catalytic Converter Replacement (1.4L LUH and LUJ) (See: Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (1.6L LDE, LXV, 1.8L 2H0, and LUW) (See: Exhaust System/Catalytic Converter/Service and Repair). 5. Remove the warm up three way catalytic converter. Refer to Warm Up Three-Way Catalytic Converter Replacement (1.4L LUH and LUJ) (See: Exhaust System/Heat Shield/Service and Repair/Warm Up Three-Way Catalytic Converter Replacement). 6. Remove the engine oil heater. Refer to Engine Oil Heater Replacement (See: Service and Repair) 7. Remove the 3 transmission to oil pan bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Page 1652 8. Remove the 16 oil pan bolts (1). Caution: Pry the oil pan carefully in order to prevent damage to the transaxle case or the oil pan sealing surfaces. 9. Position a prying tool to the area (1) shown, and gently pry the oil pan loose. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Page 1653 10. Remove the oil pan (1). Installation Procedure 1. Clean the sealing surface of the crankshaft bearing cap tie plate and the groove in the engine front cover from old gasket material, oil, dirt and grease. 2. If the oil pan is being reused, refer to Oil Pan Cleaning and Inspection (See: Service and Repair/Overhaul/59. Oil Pan Cleaning and Inspection). 3. Install the 2 EN-49980 - pins (1) to the shown oil pan screw bores. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Page 1654 Note: The sealing bead should be applied close to the inner edge of the oil pan. Take care that the oil suction gallery (4) will not get contaminated with sealing compound or dirt. The thickness of the sealing bead (3) should be 2 mm (0.0787 in). 4. Apply sealing compound to the oil pan. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers). 5. Apply sealing compound to the groove of the engine front cover (1). Note: The complete installation procedure of the oil pan should not take longer than 10 minutes. 6. Apply sealing compound around the screw bore (2) of the crankshaft bearing cap tie plate. Caution: Use care when installing the oil pan to prevent disruption of the sealing bead. The sealing bead should remain consistent until the oil pan is mated with the engine. An inconsistent sealing bead can cause an insufficient seal and result in engine damage. 7. Carefully install the oil pan. Use the following procedure: 1. Lay the oil pan on drive train and front suspension frame. 2. Hang in the oil pan to crankshaft balancer (1). 3. Guide the oil pan with the 2 EN-49980 - pins (2) and the equivalent screw bores to the engine. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Page 1655 4. Secure the oil pan with 4 oil pan bolts. 5. Remove the 2 EN-49980 - pins. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the remaining 12 oil pan bolts and hand tighten to approximately 2 Nm (18 lb in). 7. Install the 3 transmission to oil pan bolts (1) and tighten to 40 Nm (30 lb ft). 8. Tighten the 16 oil pan bolts to 10 Nm (89 lb in). 8. Install the engine oil heater. Refer to Engine Oil Heater Replacement (See: Service and Repair). 9. Install the warm up three way catalytic converter. Refer to Warm Up Three-Way Catalytic Converter Replacement (1.4L LUH and LUJ) (See: Exhaust System/Heat Shield/Service and Repair/Warm Up Three-Way Catalytic Converter Replacement). 10. Install the catalytic converter. Refer to Catalytic Converter Replacement (1.4L LUH and LUJ) (See: Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (1.6L LDE, LXV, 1.8L 2H0, and LUW) (See: Exhaust System/Catalytic Converter/Service and Repair). 11. Lower the vehicle. 12. Fill engine oil. Refer to Engine Oil and Oil Filter Replacement (See: Engine Oil/Service and Repair). 13. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Powertrain Component Views Engine Components - Right Front (LUJ) 1 - Q6E Camshaft Position Actuator Solenoid Valve - Exhaust 2 - B23E Camshaft Position Sensor Exhaust 3 - B37 Engine Oil Pressure Switch 4 - B52A Heated Oxygen Sensor 1 5 - Q42 Turbocharger Wastegate Solenoid Valve 6 - Q2 A/C Compressor Clutch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations Oil Pressure Switch (For Fuel Pump): Locations Disassembled Views Cylinder Head Assembly 1 - Camshaft Cover 2 - Oil Level Indicator 3 - Camshaft Cover Bolt 4 - Oil Filler Cap 5 - Oil Filler Cap Seal Ring 6 - Camshaft Cover Gasket 7 - Camshaft Bearing Cap Bolt 8 - Camshaft Bearing Cap 9 - Cylinder Head Bolt 10 - Valve Keys 11 - Valve Spring Retainer 12 - Valve Spring 13 Engine Lift Bracket Left Side 14 - Engine Lift Bracket Bolt 15 - Cylinder Head 16 - Intake Valve Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 1662 17 - Exhaust Valve 18 - Engine Lift Bracket 19 - Engine Lift Bracket Bolt 20 - Engine Lift Bracket 21 - Engine Lift Bracket Bolt 22 - Oil Pressure Indicator Switch 23 - Oil Pressure Indicator Switch Seal Ring 24 - Hydraulic Valve Lash Adjuster 25 - Hydraulic Valve Lash Adjuster Arm 26 - Exhaust Camshaft 27 - Intake Camshaft Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 1663 Oil Pressure Switch (For Fuel Pump): Service and Repair Engine Oil Pressure Indicator Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications The oil pressure at idle speed should be 150 kpa (22 psi) The oil pressure between 3000 - 3500 rpm should be 380 - 650 kpa (55 - 94 psi) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 1668 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing (1.4L LUH and LUJ) Special Tools * EN-498-B - Oil Pressure Gauge * EN-498-3 - Adapter For equivalent regional tools, refer to Special Tools (See: Tools and Equipment) Removal Procedure 1. Disconnect the oil pressure indicator switch wiring harness plug. 2. Remove the oil pressure indicator switch (1) and the oil pressure indicator switch seal ring (2). Measuring Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 1669 1. Install EN-498-B - gauge (1) along with EN-498-3 - adapter (2). 2. Start Engine. Note: The oil temperature should be between 80°C and 100°C. 3. Measure the oil pressure: * The oil pressure at idle speed should be 150kpa (22 psi). * The oil pressure between 3000 - 3500 rpm should be 380 - 650 kpa (55 - 94 psi). 4. Stop engine. 5. If the engine oil pressure is below specifications, inspect the engine for 1 or more of the following conditions: * Oil pump worn or dirty. Refer to Oil Pump Replacement (See: Service and Repair) and Engine Front Cover and Oil Pump Cleaning and Inspection (See: Service and Repair/Overhaul/52. Engine Front Cover and Oil Pump Cleaning and Inspection). * Oil suction gallery clogged or dirty. Refer to Oil Pan Cleaning and Inspection (See: Service and Repair/Overhaul/59. Oil Pan Cleaning and Inspection) * Cracked, porous, or restricted oil galleries. * Oil pressure relief valve malfunction. 6. Remove EN-498-B - gauge and EN-498-3 - adapter. Installation Procedure 1. Install the oil pressure indicator switch and a NEW oil pressure indicator switch seal ring. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the oil pressure indicator switch to 20 Nm (15 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Intake manifold bolts............................................................................................................................. ..........................................................20 Nm (15 lb ft) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1673 Intake Manifold: Service and Repair Intake Manifold Replacement Special Tools EN-34730-91 - Pressure Tester For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Open hood. 2. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Remove engine sight shield. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Unclip the heater outlet hose from retainer clip (1). 6. Unclip the engine control module wiring harness from 2 retainer clips (2). 7. Remove the charge air cooler outlet air hose from the throttle body. Refer to Charge Air Cooler Outlet Air Hose Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1674 8. Disconnect the throttle body wiring harness plug (1). 9. Disconnect the evaporative emission canister purge solenoid valve wiring harness plug (3). Note: Make note of the installed position of the manifold absolute pressure sensor wiring harness plugs to ensure they will be connected in their original position. 10. Disconnect the 2 manifold absolute pressure sensor wiring harness plugs (1) and (2). 11. Disconnect the 4 fuel injector wiring harness plugs (4). 12. Unclip the engine control module wiring harness from the camshaft cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1675 13. Disconnect the turbocharger wastegate regulator solenoid valve wiring harness plug (3). 14. Unclip the engine control module wiring harness from 2 intake manifold retainer clips (2) and from 2 fuel injection rail retainer clips (1). Warning Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 15. Remove fuel injector rail cap (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1676 16. Relieve the fuel system pressure. Use EN-34730-91 - pressure tester (1). 17. Disconnect the fuel feed pipe (1) from the fuel rail. 18. Unclip fuel feed pipe from the retainer clip. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1677 19. Disconnect the fuel ventilation pipe (1) from the evaporative emission canister purge solenoid valve. 20. Unclip the fuel ventilation pipe from the retainer clip. 21. Disconnect the brake booster vacuum pipe (1) from intake manifold. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1678 Note: Intake manifold bolts remain in intake manifold. 22. Remove the 6 intake manifold bolts (1). 23. Remove the intake manifold (1). 24. Remove and DISCARD the intake manifold gasket. 25. Remove the assembly parts from the intake manifold as necessary. Refer to Intake Manifold Disassemble (1.4L LUH and LUJ) (See: Service and Repair/Overhaul/48. Intake Manifold Disassemble). Installation Procedure 1. Install the assembly parts to the intake manifold as necessary. Refer to Intake Manifold Assemble (1.4L LUH and LUJ) (See: Service and Repair/Overhaul/50. Intake Manifold Assemble). 2. Clean the sealing surfaces. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1679 3. Install the intake manifold (1) along with a NEW intake manifold gasket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the 6 intake manifold bolts (1) and tighten to 20 Nm(15 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1680 5. Connect the fuel ventilation pipe (1) to the evaporative emission canister purge solenoid valve. 6. Clip in the fuel ventilation pipe to retainer clip. 7. Connect the fuel feed pipe (1) to the fuel rail. 8. Clip in the fuel feed pipe to retainer clip. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1681 9. Connect the brake booster vacuum pipe (1) to the intake manifold. 10. Install fuel injector rail cap (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1682 11. Connect the turbocharger wastegate regulator solenoid valve wiring harness plug (3). 12. Clip in the engine control module wiring harness to 2 intake manifold retainer clips (2) and from 2 fuel injection rail retainer clips (1). 13. Clip in the engine control module wiring harness to the camshaft cover. 14. Connect the 4 fuel injector wiring harness plugs (4). 15. Connect the 2 manifold absolute pressure sensor wiring harness plugs (1) and (2). 16. Disconnect the evaporative emission canister purge solenoid valve wiring harness plug (3). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1683 17. Connect the throttle body wiring harness plug (1). 18. Install the charge air cooler outlet air hose to the throttle body. Refer to Charge Air Cooler Outlet Air Hose Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair). 19. Clip in the heater outlet hose to retainer clip (1). 20. Clip in the engine control module wiring harness to 2 retainer clips (2). 21. Lower the vehicle. 22. Install the engine sight shield. 23. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 24. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Oil Seal Replacement (Automatic Transmission) Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Replacement (Automatic Transmission) Crankshaft Rear Oil Seal Replacement (Automatic Transmission) Special Tools * EN-658-1 - Installer * EN-235-6 - Installer For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Open the hood. 2. Remove the automatic transmission flexplate. Refer to Automatic Transmission Flex Plate Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair). 3. Place a collecting basin underneath the vehicle. 4. Remove the crankshaft rear oil seal. Installation Procedure 1. Install the crankshaft rear oil seal (1) with EN-235-6 - installer (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Oil Seal Replacement (Automatic Transmission) > Page 1689 2. Use EN-658-1 - installer (1) to strike the crankshaft rear oil seal. 3. Remove collecting basin. 4. Install the automatic transmission flexplate. Refer to Automatic Transmission Flex Plate Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair). 5. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Oil Seal Replacement (Automatic Transmission) > Page 1690 Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Replacement (Manual Transmission) Crankshaft Rear Oil Seal Replacement (Manual Transmission) Special Tools * EN-658-1 - Installer * EN-235-6 - Installer For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Open the hood. 2. Remove the engine flywheel. Refer to Engine Flywheel Replacement (1.4L LUH and LUJ) (See: Transmission and Drivetrain/Flywheel/Service and Repair). 3. Place a collecting basin underneath the vehicle. 4. Remove the crankshaft rear oil seal. Installation Procedure 1. Install the crankshaft rear oil seal (1) with EN-235-6 - installer (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Oil Seal Replacement (Automatic Transmission) > Page 1691 2. Use EN-658-1 - installer (1) to strike the crankshaft rear oil seal. 3. Remove collecting basin. 4. Install the engine flywheel. Refer to Engine Flywheel Replacement (1.4L LUH and LUJ) (See: Transmission and Drivetrain/Flywheel/Service and Repair). 5. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Front Oil Seal Replacement Special Tools * EN-960 - Installer * EN-45000 - Remover Oil seal For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Open the hood. 2. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair). 3. Place collecting basin underneath. 4. Remove crankshaft front oil seal (2) from engine front cover. Use EN-45000 - remover (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 1695 1. Install NEW crankshaft front oil seal (1) to EN-960 - installer (2). 2. Install crankshaft front oil seal by means of EN-960 - installer (1) to engine front cover (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 1696 3. Ensure that crankshaft front oil seal (2) is flush with engine front cover (1). 4. Install crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair). 5. Remove collecting basin. 6. Check and correct engine oil level. 7. Close hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement Special Tools * EN-958 - Installer * EN-6086 - Basic Kit, Spring and Wedge Replacer * EN-840 - Pliers / Remover * EN-952 - Fixing Pin For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the front compartment splash shield right side. Refer to Front Compartment Splash Shield Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Splash Shield Replacement). 3. Lower the vehicle. 4. Remove the hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm Replacement (See: Camshaft, Lifters and Push Rods/Lifter / Lash Adjuster/Service and Repair/Hydraulic Valve Lash Adjuster Arm Replacement). 5. Remove the spark plugs. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). Note: Wheels must contact the ground. 6. Shift to 5. gear (MT) or park position (AT) and apply the park brake. 7. Adjust the engine to TDC of cylinder 1 and fix the crankshaft. Refer to Camshaft Timing Chain Adjustment (See: Service and Repair/Overhaul/4. Camshaft Timing Chain Adjustment). 8. Mark the crankshaft balancer 180° opposed to the cylinder 1 TDC marking. Intake Valve Stem Oil Seal Removal Cylinder 1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 1700 1. Prepare the 2 EN-6086-6 - supports (1) for the installation by tightening the support head in a centered position to the rail with the bolt (2). 2. Install the EN-6086-5 - mounting shaft (3) along with the 2 EN-6086-6 - supports (4) and the EN-6086-8 - handle to the cylinder head. Note: The demounting piece must point to the intake side. 3. Install the EN-6086-7 - lever (2) along with the EN-6086-11 - demounting piece (1) to the mounting shaft. 4. Position the mounting shaft centered above the spark plug bores and tighten the 4 fasteners (6). 5. Install the EN-6086-15 - pneumatic adapter (5) to the spark plug screw bore of cylinder 1. 6. Apply air pressure to cylinder 1. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 1701 7. Remove the valve keys, valve spring retainers and the valve springs of the intake valves of cylinder 1, using the following procedure: Caution: The demounting piece part of EN-6086 Basic Kit, Spring and Wedge Replacer must be applied parallel to the valve retainers in order to prevent damage to the tools or the valve train components. If demounting piece is not applied parallel it could cause damage to the valve stem keys or the valve retainers. 1. Apply tension to the valve springs, using the EN-6086-7 - lever (1) and the EN-6086-11 demounting piece (2) until the valve keys are discharged from spring load and remove the valve keys. 2. Release tension from the valve springs and remove the valve spring retainers and the valve springs. 8. Remove the intake valve stem oil seals (2) of cylinder 1, using the EN-840 - pliers (1). Intake Valve Stem Oil Seal Installation Cylinder 1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 1702 Note: Lubricate the NEW intake valve stem oil seals with clean engine oil. 1. Install the NEW intake valve stem oil seals of cylinder 1, using the EN-958 - installer (1). 2. Prepare the EN-6086-200-1 - mounting piece for the valve key installation. The mounting piece must be assembled in the following order: 1. Support (6) 2. Bushing (5) 3. Spring (4) 4. EN-6086-200-10 - plunger (3) 5. Screw Connection (2) 6. Lever Adapter (1) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 1703 3. Install the valve keys (1) to the mounting piece (2) and fix them with the bushing. 4. Install the intake valve springs, the intake valve spring retainers and the intake valve keys, using the following procedure: 1. Replace the EN-6086-11 - demounting piece with the assembled EN-6086-200-1 - mounting piece (1). 2. Install the intake valve springs and the intake valve spring retainers to the cylinder head. Caution: The demounting piece part of EN-6086 Basic Kit, Spring and Wedge Replacer must be applied parallel to the valve retainers in order to prevent damage to the tools or the valve train components. If demounting piece is not applied parallel it could cause damage to the valve stem keys or the valve retainers. Note: The cone side of the valve keys must point to the valve stem. 3. Push down the mounting piece (1) using the lever (2) until the valve keys are hearable engaged. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 1704 4. Inspect the intake valve keys (1) for proper seat. Exhaust Valve Stem Oil Seal Removal Cylinder 1 Remove the exhaust valve stem oil seals of cylinder 1: 1. Transfer the EN-6086-7 - lever to the exhaust side of cylinder 1. 2. Replace the EN-6086-200-1 mounting piece with the EN-6086-11 - demounting piece. 3. Remove the exhaust valve keys, exhaust valve spring retainers, exhaust valve springs and the exhaust valve stem oil seals as described above. Exhaust Valve Stem Oil Seal Installation Cylinder 1 1. Replace the EN-6086-11 - demounting piece with the assembled EN-6086-200-1 - mounting piece (1). 2. Install the exhaust valve keys, exhaust valve spring retainers, exhaust valve springs and the exhaust valve stem oil seals of cylinder 1 as described above. Intake Valve Stem Oil Seal Removal Cylinder 4 1. Release the air pressure from cylinder 1. 2. Transfer the EN-6086-15 - pneumatic adapter from cylinder 1 to the spark plug bore of cylinder 4. 3. Apply air pressure to cylinder 4. 4. Transfer the EN-6086-7 - lever to the intake side of cylinder 4. 5. Replace the EN-6086-200-1 - mounting piece with the EN-6086-11 - demounting piece. 6. Remove the intake valve keys, intake valve spring retainers, intake valve springs and the intake valve stem oil seals of cylinder 4 as described above. Intake Valve Stem Oil Seal Installation Cylinder 4 1. Replace the EN-6086-11 - demounting piece with the assembled EN-6086-200-1 - mounting piece. 2. Install the intake valve keys, intake valve spring retainers, intake valve springs and the intake valve stem oil seals of cylinder 4 as described above. Exhaust Valve Stem Oil Seal Removal And Installation Cylinder 4 Replace the exhaust valve keys, exhaust valve spring retainers, exhaust valve springs and the exhaust valve stem oil seals of cylinder 4 as described above. Intake Valve Stem Oil Seal Removal Cylinder 2 1. Release the air pressure from cylinder 4. 2. Raise the vehicle. 3. Remove the EN-952 - fixing pin from the crankshaft. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 1705 4. Rotate the crankshaft balancer in engine rotation direction until the 180° opposite marking (2) aligns with the marking (1) on the engine front cover. 5. Lower the vehicle. Note: Wheels must contact the ground. 6. Block the engine by shifting the 5. gear (MT) or park position (AT) and applying the park brake. 7. Transfer the EN-6086-15 - pneumatic adapter from cylinder 4 to the spark plug bore of cylinder 2. 8. Apply air pressure to cylinder 2. 9. Transfer the EN-6086-7 - lever to the intake side of cylinder 2. 10. Replace the EN-6086-200-1 - mounting piece with the EN-6086-11 - demounting piece. 11. Remove the intake valve keys, intake valve spring retainers, intake valve springs and the intake valve stem oil seals of cylinder 2 as described above. Intake Valve Stem Oil Seal Installation Cylinder 2 1. Transfer the EN-6086-7 - lever to the exhaust side of cylinder 2. 2. Replace the EN-6086-11 demounting piece with the assembled EN-6086-200-1 - mounting piece (1). 3. Install the intake valve keys, intake valve spring retainers, intake valve springs and the intake valve stem oil seals of cylinder 2 as described above. Exhaust Valve Stem Oil Seal Removal And Installation Cylinder 2 Replace the exhaust valve keys, exhaust valve spring retainers, exhaust valve springs and the exhaust valve stem oil seals of cylinder 2 as described above. Intake Valve Stem Oil Seal Removal Cylinder 3 1. Release the air pressure from cylinder 2. 2. Transfer the EN-6086-15 - pneumatic adapter from cylinder 2 to the spark plug bore of cylinder 3. 3. Apply air pressure to cylinder 3. 4. Transfer the EN-6086-7 - lever to the intake side of cylinder 3. 5. Replace the EN-6086-200-1 - mounting piece with the EN-6086-11 - demounting piece. 6. Remove the intake valve keys, intake valve spring retainers, intake valve springs and the intake valve stem oil seals of cylinder 3 as described above. Intake Valve Stem Oil Seal Installation Cylinder 3 1. Transfer the EN-6086-7 - lever to the exhaust side of cylinder 3. 2. Replace the EN-6086-11 demounting piece with the assembled EN-6086-200-1 - mounting piece. 3. Install the intake valve keys, intake valve spring retainers, intake valve springs and the intake valve stem oil seals of cylinder 3 as described above. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 1706 Exhaust Valve Stem Oil Seal Removal And Installation Cylinder 3 Replace the exhaust valve keys, exhaust valve spring retainers, exhaust valve springs and the exhaust valve stem oil seals of cylinder 3 as described above. Installation Procedure 1. Release air pressure from cylinder 3. 2. Remove the EN-6086-15 - pneumatic adapter. 3. Remove all parts of EN-6086 - spring and wedge replacer. 4. Shift to neutral gear and release the park brake. 5. Adjust the engine to TDC of cylinder 1 and fix the crankshaft with EN-952 - fixing pin. 6. Install the spark plugs. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). 7. Install the hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm Replacement (See: Camshaft, Lifters and Push Rods/Lifter / Lash Adjuster/Service and Repair/Hydraulic Valve Lash Adjuster Arm Replacement). 8. Raise the vehicle. 9. Remove the EN-952 - fixing pin and install the crankshaft bearing cap tie plate hole plug. Refer to Camshaft Timing Chain Adjustment (See: Service and Repair/Overhaul/4. Camshaft Timing Chain Adjustment). 10. Install the front compartment splash shield right side. Refer to Front Compartment Splash Shield Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Splash Shield Replacement). 11. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Powertrain Component Views Engine Components - Right Front (LUJ) 1 - Q6E Camshaft Position Actuator Solenoid Valve - Exhaust 2 - B23E Camshaft Position Sensor Exhaust 3 - B37 Engine Oil Pressure Switch 4 - B52A Heated Oxygen Sensor 1 5 - Q42 Turbocharger Wastegate Solenoid Valve 6 - Q2 A/C Compressor Clutch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations Oil Pressure Switch (For Fuel Pump): Locations Disassembled Views Cylinder Head Assembly 1 - Camshaft Cover 2 - Oil Level Indicator 3 - Camshaft Cover Bolt 4 - Oil Filler Cap 5 - Oil Filler Cap Seal Ring 6 - Camshaft Cover Gasket 7 - Camshaft Bearing Cap Bolt 8 - Camshaft Bearing Cap 9 - Cylinder Head Bolt 10 - Valve Keys 11 - Valve Spring Retainer 12 - Valve Spring 13 Engine Lift Bracket Left Side 14 - Engine Lift Bracket Bolt 15 - Cylinder Head 16 - Intake Valve Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 1714 17 - Exhaust Valve 18 - Engine Lift Bracket 19 - Engine Lift Bracket Bolt 20 - Engine Lift Bracket 21 - Engine Lift Bracket Bolt 22 - Oil Pressure Indicator Switch 23 - Oil Pressure Indicator Switch Seal Ring 24 - Hydraulic Valve Lash Adjuster 25 - Hydraulic Valve Lash Adjuster Arm 26 - Exhaust Camshaft 27 - Intake Camshaft Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 1715 Oil Pressure Switch (For Fuel Pump): Service and Repair Engine Oil Pressure Indicator Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Tighten the intake camshaft sprocket bolt (4) while holding the hexagon (1) of the intake camshaft to.................................................................................................................................50 Nm (37 lb ft) while holding the hexagon (1) of the intake camshaft an additional....................................................................................................................................60° Tighten the exhaust camshaft sprocket bolt while holding the hexagon of the exhaust camshaft to....................................................................................................................................50 Nm (37 lb ft) while holding the hexagon of the exhaust camshaft an additional.......................................................................................................................................60° Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Page 1720 Camshaft Gear/Sprocket: Service and Repair Camshaft Intake Sprocket Replacement Special Tool EN-955-1 - Fixing Pin from EN-955 - Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Open the hood. 2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.4L LUH and LUJ) (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 3. Remove the camshaft cover. Refer to Camshaft Cover Replacement (1.4L LUH and LUJ) (See: Cylinder Head Assembly/Valve Cover/Service and Repair). 4. Remove the 2 camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid Valve Removal (See: Service and Repair/Overhaul/25. Camshaft Position Actuator Solenoid Valve Removal). 5. Adjust the engine to TDC. Refer to Camshaft Timing Chain Inspection (See: Service and Repair/Overhaul/3. Camshaft Timing Chain Inspection). 6. Remove the timing chain tensioner plug (1) from the engine front cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Page 1721 7. Install a wrench (1) to the hexagon of the intake camshaft and rotate it in direction of the arrow in order to apply tension to the timing chain and hold. 8. Install EN-955-1 - pin (2) to the timing chain tensioner bore (1) to secure it in place. 9. Remove the wrench from the intake camshaft. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Page 1722 10. Remove the 2 upper timing chain guide bolts (1). 11. Remove the upper timing chain guide (2). 12. Loosen the intake camshaft sprocket bolt (2) while holding the hexagon of the intake camshaft with a wrench (1). 13. Loosen the exhaust camshaft sprocket bolt while holding the hexagon of the exhaust camshaft with a wrench. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Page 1723 14. Remove the 2 camshaft sprocket bolts (2) and the 2 camshaft position exciter wheels (1). 15. Remove the 2 camshaft sprockets (2) along with the timing chain (1) and place it in the engine front cover. 16. Remove the intake camshaft sprocket. Installation Procedure 1. Insert the intake camshaft sprocket to the engine to engine front cover and timing chain. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Page 1724 2. Install the 2 camshaft sprockets (2) along with the timing chain (1) to the camshafts. 3. Install the 2 camshaft sprocket bolts (2) and the 2 camshaft position exciter wheels (1). 4. Remove EN-955-1 - pin to apply tension to the timing chain. Note: Engine must be adjusted to TDC. 5. Tighten the 2 camshaft sprockets. Refer to Camshaft Timing Chain Adjustment (See: Service and Repair/Overhaul/4. Camshaft Timing Chain Adjustment). 6. Remove all special tools for timing chain adjustment. Refer to Camshaft Timing Chain Adjustment (See: Service and Repair/Overhaul/4. Camshaft Timing Chain Adjustment). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Page 1725 7. Install the upper timing chain guide (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 8. Install the 2 upper timing chain guide bolts (1) and tighten to 8 Nm (71 lb in). 9. Install the 2 camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid Valve Installation (See: Service and Repair/Overhaul/74. Camshaft Position Actuator Solenoid Valve Installation) 10. Install the camshaft cover. Refer to Camshaft Cover Replacement (1.4L LUH and LUJ) (See: Cylinder Head Assembly/Valve Cover/Service and Repair). 11. Install the timing chain tensioner plug and tighten to 50 Nm (37 lb ft). 12. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.4L LUH and LUJ) (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 13. Check and correct engine oil level. 14. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair Timing Chain: Service and Repair Camshaft Timing Chain Replacement Special Tools EN-955-1 - Fixing Pin from EN-955 - Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Open the hood. 2. Remove the engine front cover with oil pump. Refer to Engine Front Cover with Oil Pump Replacement (See: Timing Cover/Service and Repair). 3. Push the timing chain (2) in direction to the timing chain tensioner (1) and secure the tensioner with EN-955-1 - fixing pin (3). 4. Remove the 2 upper timing chain guide bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 1729 5. Remove the upper timing chain guide (2). 6. Remove the 2 timing chain guide right side bolts (2). 7. Remove the timing chain guide right side (1). 8. Remove the timing chain tensioner shoe bolt (2). 9. Remove the timing chain tensioner shoe (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 1730 10. Remove the timing chain (1) along with the crankshaft sprocket (2). 11. Remove the engine front cover gasket (1). Installation Procedure 1. Clean the engine front cover sealing surfaces on the engine block and the cylinder head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 1731 Note: The thickness of the sealing bead should be 2 mm (0.0787 in). 2. Apply sealing compound to the shown areas (1) and (2). Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers). Note: Mind the guide sleeves. 3. Install the engine front cover gasket (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 1732 4. Install the timing chain (1) along with the crankshaft sprocket (2). 5. Install the timing chain tensioner shoe (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the timing chain tensioner shoe bolt (2) and tighten to 20 Nm (15 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 1733 7. Install the timing chain guide right side (1). 8. Install the 2 timing chain guide right side bolts (2) and tighten to 8 Nm (71 lb in). 9. Push the timing chain (2) in direction to the timing chain tensioner (1) and Remove EN-955-1 fixing pin (3). 10. Install the engine front cover with oil pump. Refer to Engine Front Cover with Oil Pump Replacement (See: Timing Cover/Service and Repair). 11. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications Timing chain tensioner bolts (2) and tighten to.................................................................................................................................................8 Nm (71 lb ft) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 1737 Timing Chain Tensioner: Service and Repair Timing Chain Tensioner Replacement Special Tools EN-955-1 - Fixing Pin from EN-955 - Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Open the hood. 2. Remove the engine front cover with oil pump. Refer to Engine Front Cover with Oil Pump Replacement (See: Timing Cover/Service and Repair). Note: Removal of timing chain is necessary to get access to the engine front cover gasket. 3. Remove the camshaft timing chain. Refer to Camshaft Timing Chain Replacement (See: Timing Chain/Service and Repair). 4. Remove the EN-955-1 - pin (1) from timing chain tensioner. 5. Remove the 2 timing chain tensioner bolts (2). 6. Remove the timing chain tensioner (3). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 1738 1. Install the timing chain tensioner (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 2 timing chain tensioner bolts (2) and tighten to 8 Nm (71 lb ft). 3. Fix the timing chain tensioner with EN-955-1 - pin (1) 4. Install the engine front cover gasket and the camshaft timing chain. Refer to Camshaft Timing Chain Replacement (See: Timing Chain/Service and Repair). 5. Install the engine front cover with oil pump. Refer to Engine Front Cover with Oil Pump Replacement (See: Timing Cover/Service and Repair). 6. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Engine Front Cover Bolts M10............................................................................................................. ....................................................................................................35 Nm (26 lb ft) M6........................... .............................................................................................................................................................. ...........................8 Nm (71 lb in) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1742 Timing Cover: Service and Repair Engine Front Cover with Oil Pump Replacement Removal Procedure 1. Open the hood. 2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Set the engine to TDC. Refer to Camshaft Timing Chain Inspection (See: Service and Repair/Overhaul/3. Camshaft Timing Chain Inspection). 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the front compartment splash shield right side. Refer to Front Compartment Splash Shield Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Splash Shield Replacement). 6. Disconnect all electrical connectors from the generator. Refer to Generator Replacement (1.4L LDD, LUH, and LUJ) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Replacement (1.6L LDE, LXV, LLU, 1.8L 2H0, and LUW) (See: Starting and Charging/Charging System/Alternator/Service and Repair). 7. Fix the drive belt tensioner and remove the drive belt from crankshaft balancer, drive belt tensioner and air conditioning compressor. Refer to Drive Belt Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 8. Remove the air conditioning compressor bracket. Refer to Air Conditioning Compressor Bracket Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Service and Repair). 9. Place a collecting basin underneath. 10. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair). 11. Remove the oil pan. Refer to Oil Pan Replacement (1.4L LUH and LUJ) (See: Engine Lubrication/Oil Pan/Service and Repair). 12. Lower vehicle. 13. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side (See: Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Removal and Replacement/Engine Mount Bracket Replacement - Right Side). 14. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt Tensioner/Service and Repair). 15. Remove the generator from above. Refer to Generator Replacement (1.4L LDD, LUH, and LUJ) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Replacement (1.6L LDE, LXV, LLU, 1.8L 2H0, and LUW) (See: Starting and Charging/Charging System/Alternator/Service and Repair). 16. Remove the water pump pulley and the water pump. Refer to Water Pump Replacement (LDD and LUJ) (See: Water Pump/Service and Repair )Water Pump Replacement (LDE, LXV, 2H0, and LUW) (See: Water Pump/Service and Repair). 17. Remove the camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid Valve Removal (See: Service and Repair/Overhaul/25. Camshaft Position Actuator Solenoid Valve Removal). 18. Loosen the camshaft sprocket bolts until the camshaft position exciter wheels are free rotatable. Refer to Camshaft Timing Chain Adjustment ( See: Service and Repair/Overhaul/4. Camshaft Timing Chain Adjustment). 19. Remove the 13 engine front cover bolts M6 (1). 20. Remove the 2 engine front cover bolts M10 (2). 21. Remove the engine front cover (3). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1743 Note: Removal of timing chain is necessary to get access to engine front cover gasket. 22. Remove the camshaft timing chain. Refer to Camshaft Timing Chain Replacement (See: Timing Chain/Service and Repair). 23. Remove the engine front cover gasket (1). 24. Remove the intake and exhaust camshaft position sensors from the engine front cover. Refer to Engine Front Cover and Oil Pump Disassemble ( See: Service and Repair/Overhaul/53. Engine Front Cover and Oil Pump Disassemble). Installation Procedure 1. Install the intake and exhaust camshaft position sensors to the engine front cover. Refer to Engine Front Cover and Oil Pump Assemble (See: Service and Repair/Overhaul/96. Engine Front Cover and Oil Pump Assemble). 2. Clean the engine front cover sealing surfaces on engine block and cylinder head. Note: The thickness of the sealing bead should be 2 mm (0.0787 in). 3. Apply sealing compound to the shown areas (1) and (2). Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1744 Note: Mind the guide sleeves. 4. Install a NEW engine front cover gasket (1). 5. Install the timing chain. Refer to Camshaft Timing Chain Replacement (See: Timing Chain/Service and Repair). Note: Mind the guide sleeves when installing the engine front cover. The complete installation procedure of the engine front cover should not take longer than 10 minutes. 6. Install the engine front cover (3). 7. Install the 13 engine front cover bolts M6 (1). 8. Install the 2 engine front cover bolts M10 (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Tighten the 13 engine front cover bolts M6 to 8 Nm (71 lb in). 10. Tighten the 2 engine front cover bolts M10 to 35 Nm (26 lb ft). Note: Engine should be adjusted and fixed in TDC position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1745 11. Tighten the camshaft sprockets, install the upper timing chain guide and remove all special tools. Refer to Camshaft Timing Chain Adjustment ( See: Service and Repair/Overhaul/4. Camshaft Timing Chain Adjustment). 12. Install the 2 camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid Valve Replacement (See: Variable Valve Timing/Variable Valve Timing Solenoid/Service and Repair). 13. Install the water pump and the water pump pulley. Refer to Water Pump Replacement (LDD and LUJ) (See: Water Pump/Service and Repair )Water Pump Replacement (LDE, LXV, 2H0, and LUW) (See: Water Pump/Service and Repair). 14. Install the generator from above. Refer to Generator Replacement (1.4L LDD, LUH, and LUJ) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Replacement (1.6L LDE, LXV, LLU, 1.8L 2H0, and LUW) (See: Starting and Charging/Charging System/Alternator/Service and Repair). 15. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt Tensioner/Service and Repair). 16. Install the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side (See: Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Removal and Replacement/Engine Mount Bracket Replacement - Right Side). 17. Loosely install the drive belt to water pump pulley and generator pulley. 18. Install the engine mount. Refer to Engine Mount Replacement - Right Side (See: Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Removal and Replacement/Engine Mount Replacement - Right Side). 19. Remove engine lifter from engine lift bracket. 20. Install the camshaft cover. Refer to Camshaft Cover Replacement (1.4L LUH and LUJ) (See: Cylinder Head Assembly/Valve Cover/Service and Repair). 21. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.4L LUH and LUJ) (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 22. Raise the vehicle. 23. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair). 24. Install the oil pan. Refer to Oil Pan Replacement (1.4L LUH and LUJ) (See: Engine Lubrication/Oil Pan/Service and Repair). 25. Install the air conditioning compressor bracket. Refer to Air Conditioning Compressor Bracket Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Service and Repair). 26. Install the drive belt to crankshaft balancer, drive belt tensioner and air conditioning compressor. Refer to Drive Belt Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 27. Connect all electrical connectors to the generator. Refer to Generator Replacement (1.4L LDD, LUH, and LUJ) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Replacement (1.6L LDE, LXV, LLU, 1.8L 2H0, and LUW) (See: Starting and Charging/Charging System/Alternator/Service and Repair). 28. Install the front compartment splash shield right side. Front Compartment Splash Shield Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Splash Shield Replacement). 29. Lower the vehicle 30. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 31. Fill up engine oil. Refer to Engine Oil and Oil Filter Replacement (See: Engine Lubrication/Engine Oil/Service and Repair). 32. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle Variable Valve Timing Actuator: Customer Interest Engine - Lack of Power with Multiple DTCs or Rattle TECHNICAL Bulletin No.: 10-06-04-016 Date: December 20, 2010 Subject: Engine Lack of Power with DTCs P0011, P0014, P000A, P000B, P0012, P0015 or Engine Rattle Noise (Remove Oil Filters from Intake and Exhaust Camshaft Position Actuator Solenoid Valves) Models: 2008-2011 Chevrolet Aveo 2011 Chevrolet Cruze (US and Canada) 2009-2011 Chevrolet Cruze (Export Only) 2008-2009 Pontiac G3, Wave 2008-2009 Saturn Astra Condition Some customers may comment on lack of power with the following DTCs or an engine rattle noise from the sprockets. Cruze GEN3 1.6/1.8D - P0011: Intake Camshaft Position (CMP) System Performance - P0014: Exhaust Camshaft Position (CMP) System Performance - P000A: Intake Camshaft Position System Slow Response - P000B: Exhaust Camshaft Position System Slow Response Aveo GEN3 1.4D - P0012: Intake Camshaft Position (CMP) System Performance Bank 1-Retarded - P0015: Exhaust Camshaft Position (CMP) System Performance Bank 1-Retarded Aveo/G3/Wave Gen3 1.6D - P0011: Intake Camshaft Position (CMP) System Performance Bank 1 - P0014: Exhaust Camshaft Position (CMP) System Performance Bank 1 Correction Remove four oil filters from the intake and exhaust camshaft position actuator solenoid valves. 1. Open the hood. 2. Disconnect the negative battery cable. 3. Disconnect the camshaft position actuator solenoid valve connectors. 4. Remove the power steering line bracket bolt and reposition the bracket (for 1.6/1.8L only). 5. Disconnect PCV pipe and reposition (for 1.6/1.8L only). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 1755 6. Remove the camshaft position actuator solenoid valve bolts. 7. Remove the camshaft position actuator solenoid valves and seals. 8. Check whether the filter is broken or not (1). 9. Remove the four filters (intake and exhaust). 1. Broken Filter: Remove filter with a blunt tool. 2. Unbroken Filter 1. Locate the filter hinge between the holes. 2. Cut the filter hinge slightly. Caution Do not scratch the valve surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 1756 3. Remove the filter with a blunt tool. 10. Install the camshaft position actuator solenoid valves and seals. Coat the seal with clean engine oil prior to installation. 11. Install the camshaft position actuator solenoid valve bolts. Tighten Tighten the bolts to 6 Nm (53 lb in). 12. Connect the camshaft position actuator solenoid valve connectors. 13. Reposition and install the PCV pipe (for 1.6/1.8 only). 14. Reposition the power steering bracket and install the power steering line bracket bolt (for 1.6/1.8 only). 15. Connect the negative battery cable. Note If an engine rattle noise is heard after removing the filters, refer to SI for further diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle Variable Valve Timing Actuator: All Technical Service Bulletins Engine - Lack of Power with Multiple DTCs or Rattle TECHNICAL Bulletin No.: 10-06-04-016 Date: December 20, 2010 Subject: Engine Lack of Power with DTCs P0011, P0014, P000A, P000B, P0012, P0015 or Engine Rattle Noise (Remove Oil Filters from Intake and Exhaust Camshaft Position Actuator Solenoid Valves) Models: 2008-2011 Chevrolet Aveo 2011 Chevrolet Cruze (US and Canada) 2009-2011 Chevrolet Cruze (Export Only) 2008-2009 Pontiac G3, Wave 2008-2009 Saturn Astra Condition Some customers may comment on lack of power with the following DTCs or an engine rattle noise from the sprockets. Cruze GEN3 1.6/1.8D - P0011: Intake Camshaft Position (CMP) System Performance - P0014: Exhaust Camshaft Position (CMP) System Performance - P000A: Intake Camshaft Position System Slow Response - P000B: Exhaust Camshaft Position System Slow Response Aveo GEN3 1.4D - P0012: Intake Camshaft Position (CMP) System Performance Bank 1-Retarded - P0015: Exhaust Camshaft Position (CMP) System Performance Bank 1-Retarded Aveo/G3/Wave Gen3 1.6D - P0011: Intake Camshaft Position (CMP) System Performance Bank 1 - P0014: Exhaust Camshaft Position (CMP) System Performance Bank 1 Correction Remove four oil filters from the intake and exhaust camshaft position actuator solenoid valves. 1. Open the hood. 2. Disconnect the negative battery cable. 3. Disconnect the camshaft position actuator solenoid valve connectors. 4. Remove the power steering line bracket bolt and reposition the bracket (for 1.6/1.8L only). 5. Disconnect PCV pipe and reposition (for 1.6/1.8L only). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 1762 6. Remove the camshaft position actuator solenoid valve bolts. 7. Remove the camshaft position actuator solenoid valves and seals. 8. Check whether the filter is broken or not (1). 9. Remove the four filters (intake and exhaust). 1. Broken Filter: Remove filter with a blunt tool. 2. Unbroken Filter 1. Locate the filter hinge between the holes. 2. Cut the filter hinge slightly. Caution Do not scratch the valve surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 1763 3. Remove the filter with a blunt tool. 10. Install the camshaft position actuator solenoid valves and seals. Coat the seal with clean engine oil prior to installation. 11. Install the camshaft position actuator solenoid valve bolts. Tighten Tighten the bolts to 6 Nm (53 lb in). 12. Connect the camshaft position actuator solenoid valve connectors. 13. Reposition and install the PCV pipe (for 1.6/1.8 only). 14. Reposition the power steering bracket and install the power steering line bracket bolt (for 1.6/1.8 only). 15. Connect the negative battery cable. Note If an engine rattle noise is heard after removing the filters, refer to SI for further diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Page 1764 Variable Valve Timing Actuator: Description and Operation Camshaft Actuator System Description Circuit/System Description The camshaft position actuator solenoid valve - intake and camshaft position actuator solenoid valve - exhaust system enables the engine control module (ECM) to change camshaft timing while the engine is running. The camshaft position actuator assembly varies camshaft position in response to directional changes in oil pressure. The camshaft position actuator solenoid valve Intake and camshaft position actuator solenoid valve - exhaust controls the oil pressure that is applied to advance or retard the camshaft. Modifying camshaft timing under changing engine demand provides better balance between the following performance concerns: * Engine power output * Fuel economy * Lower exhaust emissions The camshaft position actuator solenoid valve - intake and camshaft position actuator solenoid valve - exhaust is controlled by the ECM. The crankshaft position sensor and the camshaft position sensor - intake and camshaft position sensor - exhaust are used to monitor changes in camshaft position. The ECM uses information from the following sensors in order to calculate the desired camshaft position: * Engine coolant temperature (ECT) sensor * Mass air flow (MAF) sensor * Throttle position sensor * Vehicle speed sensor (VSS) Camshaft Position Actuator System Operation The ECM operates the camshaft position actuator solenoid valve - intake and camshaft position actuator solenoid valve - exhaust by pulse width modulation (PWM) of the solenoid coil. The higher the PWM duty cycle, the larger the change in camshaft timing. Oil pressure that is applied to the advance side of the fixed vanes will rotate the camshaft in a clockwise direction. The clockwise movement of the camshaft will advance the timing up to a maximum of 21°. When oil pressure is applied to the return side of the vanes, the camshaft will rotate counterclockwise until returning to 0°. Oil flowing to the camshaft position actuator solenoid valve - intake and camshaft position actuator solenoid valve - exhaust housing from the camshaft position actuator solenoid valve - Intake and camshaft position actuator solenoid valve - exhaust advance passage applies pressure to the advance side of the vane wheel in the camshaft position actuator assembly. At the same time the camshaft position actuator solenoid valve - Intake and camshaft position actuator solenoid valve exhaust retard passage is open, allowing oil pressure to decrease on the retard side of the vane wheel. These two simultaneous actions cause the vane wheel to rotate clockwise, advancing camshaft advance timing. When the oil flowing to the camshaft position actuator solenoid valve - Intake and camshaft position actuator solenoid valve - exhaust housing is from the camshaft position actuator solenoid valve Intake and camshaft position actuator solenoid valve - exhaust retard passage, oil pressure is applied to the retard side of the vane wheel. Because the solenoid advance passage is open, allowing oil pressure to decrease on the advance side of the vane wheel, the camshaft position retards. The ECM can also command the camshaft position actuator solenoid valve - Intake and camshaft position actuator solenoid valve - exhaust to stop oil flow from both passages in order to hold the current camshaft position. The ECM is continuously comparing camshaft position sensor - intake and camshaft position sensor - exhaust input with camshaft position actuator solenoid valve Intake and camshaft position actuator solenoid valve - exhaust input in order to monitor camshaft position and detect any system malfunctions. The following table provides camshaft phase commands for common driving conditions: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Service and Repair Variable Valve Timing Solenoid: Service and Repair Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure 1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.4L LUH and LUJ) (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 2. Disconnect the intake camshaft position actuator solenoid valve wiring harness plug (3). 3. Disconnect the exhaust camshaft position actuator solenoid valve wiring harness plug (2). 4. Unclip ECM wiring harness (1) from camshaft cover. 5. Remove the 4 camshaft position actuator solenoid valve bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Service and Repair > Page 1768 6. Carefully rotate the intake camshaft position actuator solenoid valve (1) counter clockwise as shown. 7. Carefully rotate the exhaust camshaft position actuator solenoid valve (2) clockwise as shown. Caution: The camshaft position actuator solenoid valves must be kept parallel to the engine front cover during removal and installation. The camshaft position actuator solenoid valves can be damaged if they become wedged or stuck during this process. 8. Carefully remove the 2 camshaft position actuator solenoid valves (2) and the seal rings (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Service and Repair > Page 1769 Caution: The camshaft position actuator solenoid valves must be kept parallel to the engine front cover during removal and installation. The camshaft position actuator solenoid valves can be damaged if they become wedged or stuck during this process. Note: Lubricate the seal rings with oil in order to make the installation easier. 1. Carefully install the 2 camshaft position actuator solenoid valves (2) and the 2 seal rings (1) by gently pressing into position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 4 camshaft position actuator solenoid valve bolts (1) and tighten to 8 Nm (71 lb in). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Service and Repair > Page 1770 3. The 2 camshaft position actuator solenoid valves should be installed in the position as shown (1) and (2). 4. Clip ECM wiring harness (1) to camshaft cover. 5. Connect the exhaust camshaft position actuator solenoid valve wiring harness plug (2). 6. Connect the intake camshaft position actuator solenoid valve wiring harness plug (3). 7. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.4L LUH and LUJ) (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURE Fuel Pressure (Key ON, Engine OFF).................................................................................................. .............................................250-450 kPa (36-65 PSI) Should not decrease greater than........................................................................................................ .................................................34 kPa (5 PSI) in 1 min Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1775 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description When the ignition is turned ON, the engine control module (ECM) supplies power to the in-tank fuel pump, by energizing the fuel pump relay. The in-tank fuel pump remains ON as long as the engine is cranking or running and the ECM receives crankshaft reference pulses. If there are no reference pulses, the ECM turns the in-tank fuel pump OFF, 2 s after the ignition switch is turned ON or 2 s after the engine stops running. The electric fuel pump is incorporated into the modular fuel pump and sender assembly and is located inside the fuel tank. The fuel pump supplies fuel through a fuel filter, also located in the modular fuel pump and sender assembly, through the fuel feed pipes, to the fuel rail assembly. The fuel pump provides fuel at a pressure above the pressure needed by the fuel injectors. The fuel pressure regulator, located in the modular fuel pump and sender assembly, keeps the fuel available to the fuel injectors at a regulated pressure. When the fuel pressure rises above the pressure regulator calibration, the pressure is relieved, with excess fuel exhausted into the modular fuel pump and sender assembly reservoir. Reference Information Description and Operation Fuel System Description (See: Powertrain Management/Computers and Control Systems/Description and Operation/Fuel System Description) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Special Tools * CH 48027 - Digital Pressure Gauge * EN 37287 - Fuel Line Shut-Off Adapters For equivalent regional tools, refer to Special Tools (See: Powertrain Management/Computers and Control Systems/Tools and Equipment). Circuit/System Verification Note: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that an adequate amount of fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. 1. Ignition ON, command the KR23A Fuel Pump Relay ON with a scan tool. You should hear the G12 Fuel Pump turn ON and OFF. ‹› If the G12 Fuel Pump does not turn ON, refer to Fuel Pump Electrical Circuit Diagnosis (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Pump Electrical Circuit Diagnosis). 2. Ignition OFF, all accessories OFF, install the CH 48027 - Digital Pressure Gauge. 3. Ignition ON, command the KR23A Fuel Pump Relay ON with a scan tool. Verify the fuel pressure is between 250-450 kPa (36-65 PSI) and remains steady for 5 m. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 1778 Circuit/System Testing Note: * The KR23A Fuel Pump Relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Do not start the engine. 1. Ignition ON, engine OFF, command the KR23A Fuel Pump Relay ON with a scan tool and observe the fuel pressure gauge while the G12 Fuel Pump is operating. Verify the fuel pressure is between 250-450 kPa (36-65 PSI). ‹› If the fuel pressure is greater than the specified range, replace the G12 Fuel Pump. ‹› If the fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all items test normal, replace the G12 Fuel Pump. * Restricted fuel feed pipe * Restricted or clogged strainer * Restricted or plugged fuel filter * Inspect the G12 Fuel Pump harness connectors and the ground circuits of the fuel pump for poor connections. Note: The fuel pressure may vary slightly when the G12 Fuel Pump stops operating. After the G12 Fuel Pump stops operating, the fuel pressure should stabilize and remain constant. 2. Verify the fuel pressure does not decrease greater than 34 kPa (5 PSI) in 1 min. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve fuel pressure. 2. Install the EN 37287 - Fuel Line Shut-Off Adapters between the fuel feed pipe and the fuel rail. 3. Open the valve on the EN 37287 - Fuel Line Shut-Off Adapters. 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the digital pressure gauge. 5. Close the valve on the EN 37287 - Fuel Line Shut-Off Adapters. 6. Verify the fuel pressure does not decrease greater than 34 kPa (5 PSI) in 1 minute. ‹› If the fuel pressure decreases more than 34 kPa (5 PSI) within the specified time, locate and replace the leaking fuel injector(s). ‹› If the fuel pressure does not decrease more than 34 kPa (5 PSI) within the specified time, replace the G12 Fuel Pump. 3. Relieve the fuel pressure to 69 kPa (10 PSI). Verify that the fuel pressure does not decrease more than 14 kPa (2 PSI) in 5 min. ‹› If the fuel pressure decreases more than the specified value, replace the G12 Fuel Pump. 4. Remove the EN 37287 - Fuel Line Shut-Off Adapters and CH 48027 - Digital Pressure Gauge. 5. Operate the vehicle within the conditions of the customers concern while monitoring fuel related parameters with a scan tool. The scan tool parameters should not indicate a lean condition. ‹› If the scan tool parameters indicate a lean condition, test for a restricted fuel feed pipe, restricted fuel filter, or poor connections at the harness connectors and ground circuits of the fuel pump. If all test normal, replace the fuel pump. 6. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls). Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 1779 Fuel Pressure: Testing and Inspection Fuel Pressure Measurement Fuel Pressure Measurement Special Tools EN-34730-91 - Pressure Tester For equivalent regional tools, refer to Special Tools (See: Powertrain Management/Computers and Control Systems/Tools and Equipment) Warning Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Remove the protective cap from the test connection. 2. Attach the EN-34730-91 - tester (1) to the test connection. 3. Start the engine. * Bleed the pressure tester at idling speed. * Collect the exiting fuel in a suitable container. * Read the fuel pressure from the pressure gauge. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 4. Detach the pressure gauge EN-34730-91 - tester from the test connection. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > System Diagnosis Idle Speed: Testing and Inspection Throttle/Idle Learn The Idle Learn Procedure listed below must be performed whenever the following occurs: The crankshaft position variation learn procedure is also required when the following service procedures have been performed, regardless of whether or not DTC P0315 00 is set: * The throttle body assembly is replaced. * The throttle body is cleaned. * The engine control module (ECM) is replaced. * The idle air control valve is replaced. * Power disconnection (battery cable, ECM fuse, etc.) (Delphi ECM only) 1. Turn the ignition ON. 2. Turn the ignition OFF for 15 s. 3. Turn the ignition ON for 5 s. 4. Turn the ignition OFF for 15 s. 5. Start the engine in park/neutral. 6. Allow the engine to run until the engine coolant temperature is greater than 85°C (185°F). 7. Turn the A/C ON for 10 s, if equipped. 8. If the vehicle is equipped with an automatic transaxle, apply the parking brake. While pressing the brake pedal, place the transaxle in drive for 10 s. 9. Turn the A/C OFF for 10 s, if equipped. 10. If the vehicle is equipped with an automatic transaxle, while pressing the brake pedal, place the transaxle in park/neutral. 11. Turn the ignition OFF. The idle learn procedure is complete. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 1788 Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Inlet Duct Replacement Air Cleaner Inlet Duct Replacement Removal Procedure 1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 2. Remove the intake air duct bolt (2). 3. Remove the intake air duct (1) Installation Procedure 1. Install the intake air duct (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 1789 2. Install and tighten the intake air duct bolt (2). 3. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement (1.4L LUH and LUJ) Removal Procedure 1. Open hood. 2. Disconnect mass air flow sensor wiring harness plug (2) from mass air flow sensor (3). 3. Unclip mass air flow sensor wiring harness retainer clip from air cleaner housing (1). 4. Remove the air cleaner outlet duct clamp (3). 5. Remove the air cleaner outlet duct (2) from air cleaner housing (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1793 6. Remove the 5 air cleaner housing bolts (1). 7. Remove the air cleaner upper housing (2) from the air cleaner lower housing (4). 8. Remove the air cleaner element (3). Installation Procedure 1. Install the air cleaner element (3). 2. Install the air cleaner upper housing (2) to the air cleaner lower housing (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 5 air cleaner housing bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1794 4. Install the air cleaner outlet duct (2) to the air cleaner housing (1). 5. Install the air cleaner outlet duct clamp (3). 6. Clip in mass air flow sensor wiring harness retainer clip to air cleaner housing (1). 7. Connect the mass air flow sensor wiring harness plug 2) to the mass air flow sensor (3). 8. Close hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Special Tools EN-34730-91 - Pressure Tester For equivalent regional tools, refer to Special Tools (See: Powertrain Management/Computers and Control Systems/Tools and Equipment). Warning Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. Warning Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Remove the fuel injector rail cap (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 1799 2. Relieve the fuel pressure. Use EN-34730-91 - pressure tester (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Ignition System Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Ignition System Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1806 Spark Plug: Application and ID Ignition System Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1807 Spark Plug: Testing and Inspection Spark Plug Inspection Spark Plug Usage 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications ( See: Application and ID) for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: * Spark plug fouling-Colder plug * Pre-ignition causing spark plug and/or engine damage-Hotter plug Spark Plug Inspection 1. Inspect the terminal post (1) for damage. * Inspect for a bent or broken terminal post (1). * Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: * Inspect the spark plug boot for damage. * Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1808 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. * Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications (See: Application and ID). An excessively wide electrode gap can prevent correct spark plug operation. * Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Application and ID). Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. * Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). * Inspect for a broken or worn side electrode (3). * Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. 5. A rattling sound indicates internal damage. 6. A loose center electrode (4) reduces the spark intensity. * Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. * Inspect for worn or missing platinum pads on the electrodes (3, 4) If equipped. * Inspect for excessive fouling. * Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Spark Plug Visual Inspection 1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: * Rich fuel mixtures * Leaking fuel injectors * Excessive fuel pressure * Restricted air filter element * Incorrect combustion * Reduced ignition system voltage output * Weak coils * Worn ignition wires * Incorrect spark plug gap * Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. * Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1809 Spark Plug: Service and Repair Spark Plug Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications All 4 cylinders must be tested to obtain valid test results. Record the readings. Maximum pressure differential............................................................................................................. .......................................................100 kPa (14.5 psi) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1813 Compression Check: Testing and Inspection Engine Compression Test Special Tools EN-48248 - Cylinder Compression Pressure Gauge For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement (1.4L LUH and LUJ) (See: Powertrain Management/Fuel Delivery and Air Induction/Throttle Body/Service and Repair/Removal and Replacement). 2. Remove the spark plugs. Refer to Spark Plug Replacement (See: Spark Plug/Service and Repair). 3. Remove the relay holder cover. 4. Remove the fuel pump relay. Note: The engine cranking time for the compression test should be less then 10 seconds and at 30 second intervals. 5. Crank the engine with the starter motor for 5 seconds to remove any foreign substances from the cylinders. 6. Prior to taking a compression reading, verify the cranking speed is greater than 300 RPM. If the cranking speed is below 300 RPM, repair the slow cranking speed condition before continuing with the compression test. 7. Install EN-48248 - gauge in the spark plug bore for the cylinder that is being checked. 8. Using the vehicle's starter motor, rotate or crank the engine for 4 compression strokes, puffs, for the cylinder being tested. 9. Observe the compression gauge and note the reading as the compression test is being performed. A normal cylinder reading will be indicated if compression builds up quickly and evenly to the specified level. An abnormal reading will be indicated if compression is low on the first compression stroke, starts increasing on the following compression strokes but does not reach the specified level. 10. Record the compression reading for the cylinder just tested. 11. Repeat steps for all remaining cylinders. All 4 cylinders must be tested to obtain valid test results. Record the readings. 12. Maximum pressure differential 100 kPa (14.5 psi). Installation Procedure 1. Install the fuel pump relay. 2. Install the relay holder cover. 3. Install the spark plugs. Refer to Spark Plug Replacement (See: Spark Plug/Service and Repair). 4. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement (1.4L LUH and LUJ) (See: Powertrain Management/Fuel Delivery and Air Induction/Throttle Body/Service and Repair/Removal and Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Drive Pulley, Water Pump > Component Information > Service and Repair Drive Pulley: Service and Repair Water Pump Pulley Replacement (LDD, LUH, and LUJ) (1.4L) Removal Procedure 1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.4L LUH and LUJ) (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 2. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side (See: Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Removal and Replacement/Engine Mount Bracket Replacement - Right Side). 3. Remove the drive belt. Refer to Drive Belt Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 4. Loosen the 3 water pump pulley bolts (2) while holding the water pump pulley hub with a wrench. 5. Remove the 3 water pump pulley bolts (2). 6. Remove the water pump pulley (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Drive Pulley, Water Pump > Component Information > Service and Repair > Page 1818 1. Install the water pump pulley (1). 2. Install the 3 water pump pulley bolts (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the 3 water pump pulley bolts to 22 Nm (16 lb ft) while holding the water pump pulley hub with a wrench. 4. Install the drive belt. Refer to Drive Belt Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 5. Install the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side (See: Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Removal and Replacement/Engine Mount Bracket Replacement - Right Side). 6. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.4L LUH and LUJ) (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System ................................................................................................................................... ................................................. 5.8 quarts (5.5 liters) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1824 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in the vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in the vehicle for five years or 240 000 km (150,000 miles), whichever occurs first. The following explains the cooling system and how to check and add coolant when it is low. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. If using this mixture, nothing else needs to be added. This mixture: Gives freezing protection down to -34°F (-37°C). Gives boiling protection up to 265°F (129°C). Protects against rust and corrosion. Will not damage aluminum parts. Helps keep the proper engine temperature. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. NOTICE: If extra inhibitors and/or additives are used in the vehicle's cooling system, the vehicle could be damaged. Use only the proper mixture of the engine coolant listed for the cooling system. Never dispose of engine coolant by putting it in the trash, pouring it on the ground, or into sewers, streams, or bodies of water. Have the coolant changed by an authorized service center, familiar with legal requirements regarding used coolant disposal. This will help protect the environment and your health. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Service and Repair Coolant Level Sensor: Service and Repair Engine Coolant Level Indicator Module Replacement (LDD, LUH, LUJ, LDE, LLU, LUW) (1.4L, 1.8L) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair Coolant Line/Hose: Service and Repair Engine Coolant Air Bleed Hose Replacement (1.4L LDD, LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Service and Repair Coolant Outlet: Service and Repair Water Outlet Replacement (1.4L LUH and LUJ) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). 2. Remove the charge air cooler outlet air hose from the throttle body. Refer to Charge Air Cooler Outlet Air Hose Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair). 3. Remove the engine coolant air bleed hose from the water outlet. Refer to Engine Coolant Air Bleed Hose Replacement (1.6L LDE, LXV, 1.8L 2H0 and LUW) (See: Coolant Line/Hose/Service and Repair)Engine Coolant Air Bleed Hose Replacement (1.4L LDD, LUH and LUJ) (See: Coolant Line/Hose/Service and Repair). 4. Remove the heater inlet hose from the water outlet. Refer to Heater Inlet Hose Replacement (1.4L LUJ) (See: Heater Hose/Service and Repair/Heater Inlet Hose Replacement)Heater Inlet Hose Replacement (1.8L LUW) (See: Heater Hose/Service and Repair/Heater Inlet Hose Replacement). 5. Remove the radiator inlet hose from the water outlet. Refer to Radiator Inlet Hose Replacement (LDD, LUH, and LUJ) (See: Radiator Hose/Service and Repair/Radiator Inlet Hose Replacement)Radiator Inlet Hose Replacement (LDE, LXV, 2H0, and LUW) (See: Radiator Hose/Service and Repair/Radiator Inlet Hose Replacement). 6. Remove the engine oil cooler inlet hose from the water outlet. Refer to Engine Oil Cooler Inlet Hose Replacement (1.4L LUH and LUJ) (See: Engine/Engine Lubrication/Oil Cooler/Service and Repair/Engine Oil Cooler Inlet Hose Replacement). 7. Disconnect the engine coolant temperature sensor (water outlet) wiring harness connector. 8. Remove the 3 water outlet bolts (3). 9. Remove the water outlet (2) and the water outlet seal ring (1). Installation Procedure 1. Clean the sealing surfaces. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Service and Repair > Page 1834 2. Install the water outlet (2) and a NEW water outlet seal ring (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 3 water outlet bolts (3) and tighten to 8 Nm (71 lb in). 4. Connect the engine coolant temperature sensor (water outlet) wiring harness connector. 5. Install the engine oil cooler inlet hose to the water outlet. Refer to Engine Oil Cooler Inlet Hose Replacement (1.4L LUH and LUJ) (See: Engine/Engine Lubrication/Oil Cooler/Service and Repair/Engine Oil Cooler Inlet Hose Replacement). 6. Install the radiator inlet hose to the water outlet. Refer to Radiator Inlet Hose Replacement (LDD, LUH, and LUJ) (See: Radiator Hose/Service and Repair/Radiator Inlet Hose Replacement)Radiator Inlet Hose Replacement (LDE, LXV, 2H0, and LUW) (See: Radiator Hose/Service and Repair/Radiator Inlet Hose Replacement). 7. Install the heater inlet hose to the water outlet. Refer to Heater Inlet Hose Replacement (1.4L LUJ) (See: Heater Hose/Service and Repair/Heater Inlet Hose Replacement)Heater Inlet Hose Replacement (1.8L LUW) (See: Heater Hose/Service and Repair/Heater Inlet Hose Replacement). 8. Install the engine coolant air bleed hose to the water outlet. Refer to Engine Coolant Air Bleed Hose Replacement (1.6L LDE, LXV, 1.8L 2H0 and LUW) (See: Coolant Line/Hose/Service and Repair)Engine Coolant Air Bleed Hose Replacement (1.4L LDD, LUH and LUJ) (See: Coolant Line/Hose/Service and Repair). 9. Install the charge air cooler outlet air hose to the throttle body. Refer to Charge Air Cooler Outlet Air Hose Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair). 10. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Service and Repair/Cooling System Draining and Filling (GE-47716 Fill) ). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair Coolant Reservoir: Service and Repair Radiator Surge Tank Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations Radiator Cooling Fan Motor: Locations Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components 1 - G105 Engine Compartment - Front Left 2 - G10 Cooling Fan Motor 3 - B34B Engine Coolant Temperature Sensor 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Page 1842 Radiator Cooling Fan Motor: Diagrams Component Connector End Views G10 Cooling Fan Motor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1846 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1847 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1848 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Resistor > Component Information > Service and Repair > Engine Coolant Fan Resistor Mount Repair Radiator Cooling Fan Resistor: Service and Repair Engine Coolant Fan Resistor Mount Repair Engine Coolant Fan Resistor Mount Repair Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Resistor > Component Information > Service and Repair > Engine Coolant Fan Resistor Mount Repair > Page 1853 Radiator Cooling Fan Resistor: Service and Repair Engine Coolant Fan Resistor Replacement (Gasoline) Engine Coolant Fan Resistor Replacement (Gasoline) Removal Procedure 1. Disconnect the negative cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Disconnect the engine coolant fan resistor wiring harness plug. 3. Remove the engine coolant fan resistor bolt (2). 4. Remove the engine coolant fan resistor (1). Installation Procedure 1. Install the engine coolant fan resistor (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Resistor > Component Information > Service and Repair > Engine Coolant Fan Resistor Mount Repair > Page 1854 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the engine coolant fan resistor bolt (2) and tighten to 4 Nm (36 lb in). 3. Connect the engine coolant fan resistor wiring harness plug. 4. Connect the negative cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Powertrain Component Views Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Powertrain Component Views Engine Components - Left Rear (LUJ) 1 - B111 Turbocharger Boost Pressure Sensor 2 - T8 Ignition Coil 3 - B68 Knock Sensor (KS) 4 Q38 Throttle Body 5 - B34 Engine Coolant Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Powertrain Component Views > Page 1860 Coolant Temperature Sensor/Switch (For Computer): Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components 1 - G105 Engine Compartment - Front Left 2 - G10 Cooling Fan Motor 3 - B34B Engine Coolant Temperature Sensor 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Engine Coolant Temperature Sensor Replacement (Radiator) Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement (Radiator) Engine Coolant Temperature Sensor Replacement (Radiator) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Engine Coolant Temperature Sensor Replacement (Radiator) > Page 1863 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement (Water Outlet) Engine Coolant Temperature Sensor Replacement (Water Outlet) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Engine Coolant Fan Shroud Replacement (AT) Fan Shroud: Service and Repair Engine Coolant Fan Shroud Replacement (AT) Engine Coolant Fan Shroud Replacement (LDE,LLU,LUJ,LUW,LXT,LXV,L2W,2HO-AT) (1.4L, 1.8L) Removal Procedure 1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). 4. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (LDD, LUH, and LUJ) (See: Radiator Hose/Service and Repair/Radiator Outlet Hose Replacement)Radiator Outlet Hose Replacement (LDE, LXV, 2H0, and LUW) (See: Radiator Hose/Service and Repair/Radiator Outlet Hose Replacement). 5. Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (LDD, LUH, and LUJ) (See: Radiator Hose/Service and Repair/Radiator Inlet Hose Replacement)Radiator Inlet Hose Replacement (LDE, LXV, 2H0, and LUW) (See: Radiator Hose/Service and Repair/Radiator Inlet Hose Replacement). 6. Remove the transmission fluid auxiliary cooler pipe. Refer to Transmission Fluid Cooler Hose/Pipe Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair/Transmission Fluid Cooler Hose/Pipe Replacement). 7. Disconnect the engine coolant fan resistor wiring harness plug (1) and remove the ground cable nut. 8. Remove the wiring harness (3). Cut the 4 clips. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Engine Coolant Fan Shroud Replacement (AT) > Page 1868 Note: You stand against driving direction. 9. Unclip the engine coolant fan shroud (1) at the shown four mounting points. 10. Remove the engine coolant fan shroud (1). Installation Procedure 1. Install the engine coolant fan shroud (1). 2. Clip in the engine coolant fan shroud (1) at the shown four mounting points. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Engine Coolant Fan Shroud Replacement (AT) > Page 1869 3. Connect the engine coolant fan resistor wiring harness plug (1). 4. Install the wiring harness (3). Install 4 NEW clips. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 5. Install the ground cable and the ground cable nut and tighten to 10 Nm (89 lb in). 6. Install the transmission fluid auxiliary cooler pipe. Refer to Transmission Fluid Cooler Hose/Pipe Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair/Transmission Fluid Cooler Hose/Pipe Replacement) 7. Install the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (LDD, LUH, and LUJ) (See: Radiator Hose/Service and Repair/Radiator Inlet Hose Replacement)Radiator Inlet Hose Replacement (LDE, LXV, 2H0, and LUW) (See: Radiator Hose/Service and Repair/Radiator Inlet Hose Replacement). 8. Install the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (LDD, LUH, and LUJ) (See: Radiator Hose/Service and Repair/Radiator Outlet Hose Replacement)Radiator Outlet Hose Replacement (LDE, LXV, 2H0, and LUW) (See: Radiator Hose/Service and Repair/Radiator Outlet Hose Replacement). 9. Top up the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). 10. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Engine Coolant Fan Shroud Replacement (AT) > Page 1870 Fan Shroud: Service and Repair Engine Coolant Fan Shroud Replacement Engine Coolant Fan Shroud Replacement (1.4L LUH and LUJ - M32-6 MZ4) Removal Procedure 1. Disconnect the negative cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Disconnect the engine coolant fan resistor wiring harness connector (1) and remove the ground cable nut. 3. Unclip and remove the wiring harness (3). Note: You stand against driving direction. 4. Unclip the engine coolant fan shroud from the four mounting points. 5. Remove the engine coolant fan shroud (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Engine Coolant Fan Shroud Replacement (AT) > Page 1871 Disassemble Procedure 1. Remove the engine coolant fan resistor (1) by uncliping the retainer clip (2). 2. Unclip the engine coolant fan resistor wiring harness (arrows) from the shroud. 3. Remove the 3 engine coolant fan motor bolts (3) from the engine coolant fan. 4. Remove the engine coolant fan. Assemble Procedure 1. Install the engine coolant fan. 2. Install the 3 engine coolant fan motor bolts (3) to the engine coolant fan and tighten. 3. Clip in the engine coolant fan resistor wiring harness (arrows) to the shroud. 4. Install the engine coolant fan resistor (1) by clipping the retainer clip (2). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Engine Coolant Fan Shroud Replacement (AT) > Page 1872 1. Install the engine coolant fan shroud (1). 2. Clip in the engine coolant fan shroud (1) to the four mounting points. 3. Install the wiring harness (3). 4. Connect the engine coolant fan resistor wiring harness connector (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the ground cable and the ground cable nut. Tighten the ground cable nut to 10 Nm (89 lb in). 6. Connect the negative cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair Heater Core: Service and Repair Heater Core Replacement Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). 2. Remove Instrument panel lower trim panel - left side. Refer to Instrument Panel Lower Trim Panel Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Trim Panel Replacement - Left Side). 3. Remove instrument outer trim cover - left side. Refer to Instrument Panel Outer Trim Cover Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Outer Trim Cover Replacement - Left Side). 4. Remove instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Pad Cover Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Trim Pad Cover Replacement). 5. Remove instrument panel bolt (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Page 1876 6. Remove heater core cover bolt (1) and heater core cover (2). 7. Remove the 2 heater core clamps (2). 8. Remove the 2 heater core tubes (3). 9. Remove the heater core (1). 10. Change the 2 heater core tube sealing rings. Installation Procedure 1. Install the heater core (1). 2. Install the 2 heater core tubes (3). 3. Tighten the 2 heater core clamps (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Page 1877 4. Install heater core cover bolt (1) and heater core cover (2). 5. Install instrument panel bolt (1). 6. Install instrument panel lower trim pad cover - left side. Refer to Instrument Panel Lower Trim Pad Cover Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Trim Pad Cover Replacement). 7. Install instrument outer trim cover - left side. Refer to Instrument Panel Outer Trim Cover Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Outer Trim Cover Replacement - Left Side). 8. Install instrument panel lower inner panel. Refer to Instrument Panel Lower Trim Panel Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Trim Panel Replacement - Left Side). 9. Bleed the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement Heater Hose: Service and Repair Heater Inlet Hose Replacement Heater Inlet Hose Replacement (1.4L LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1882 Heater Hose: Service and Repair Heater Outlet Hose Replacement Heater Outlet Hose Replacement (1.4L LUJ) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). 2. Remove 2 heater outlet hose clamps (1). 3. Remove heater outlet hose (2). 4. Remove heater outlet hose clamps (2). 5. Remove heater outlet hose (3) from radiator surge tank (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1883 1. Install heater outlet hose (3) to radiator surge tank (1). 2. Install heater outlet hose clamps (2). 3. Install heater outlet hose (2). 4. Install 2 heater outlet hose clamps (1). 5. Refill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1884 Heater Hose: Service and Repair Heater Core Outlet Tube Replacement Heater Core Outlet Tube Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1885 Heater Hose: Service and Repair Heater Core Inlet Tube Replacement Heater Core Inlet Tube Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures Radiator: Procedures Radiator Cleaning Warning NEVER spray water on a hot heat exchanger. The resulting steam could cause personal injury. Caution: The heat exchanger fins are necessary for good heat transfer. Do not brush the fins. This may cause damage to the fins, reducing heat transfer. Note: Remove bugs, leaves, dirt and other debris by blowing compressed air through the engine side of the radiator. * Some conditions may require the use of warm water and a mild detergent. * Clean the A/C condenser fins. * Clean between the A/C condenser and radiator. * Clean the radiator cooling fins. * Straighten any damaged cooling fins. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 1890 Radiator: Removal and Replacement Lower and Upper Radiator Mounting Pin Repair Lower and Upper Radiator Mounting Pin Repair Repair Procedure Note: If the radiator is leaky, replace it. Refer to Radiator Replacement (LDE, LXV, 2H0, LUW MT) (See: Radiator Replacement - MT )Radiator Replacement (LDE, LXV, 2H0, LUW - AT) (See: Radiator Replacement - AT)Radiator Replacement (1.4L LUH and LUJ - AT) (See: Radiator Replacement - AT)Radiator Replacement (1.4L LUH and LUJ - M32) (See: Radiator Replacement MT). 1. Pressure test the cooling system. Refer to Cooling System Leak Testing (See: Testing and Inspection/Component Tests and General Diagnostics). 2. Grind the fracture surface (1) with a proper tool. 3. Drill a hole in the center of the fractured surface, using a 6 mm (0.24 in) drill. 4. Install the new radiator mounting pin (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 1891 * Install the nut (3). Note: The bolt should not be longer than 35 mm (1.38 in). * Install the radiator mounting pin (2) with the bolt (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the bolt 5 Nm (45 lb in). Radiator and Charge Air Cooler Bracket Repair Radiator and Charge Air Cooler Bracket Repair 1. Remove the radiator. Refer to Radiator Replacement (LDE, LXV, 2H0, LUW - MT) (See: Radiator Replacement - MT)Radiator Replacement (LDE, LXV, 2H0, LUW - AT) (See: Radiator Replacement - AT)Radiator Replacement (1.4L LUH and LUJ - AT) (See: Radiator Replacement - AT)Radiator Replacement (1.4L LUH and LUJ - M32) (See: Radiator Replacement - MT). 2. Remove the charge air cooler. Refer to Charge Air Cooler Replacement (1.4L LUH, LUJ - M32-6 MZ4) (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Service and Repair/Charge Air Cooler Replacement - M32-6 MZ4)Charge Air Cooler Replacement (1.4L LUH, LUJ - AT) (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Service and Repair/Charge Air Cooler Replacement - AT). 3. Drill hole in the charge air cooler bracket and radiator bracket (2) using a 7 mm (0.28 in) drill. 4. Install the j-clip (3) to the radiator. 5. Install the charge air cooler to the radiator. Refer to Charge Air Cooler Replacement (1.4L LUH, LUJ - M32-6 MZ4) (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Service and Repair/Charge Air Cooler Replacement - M32-6 MZ4)Charge Air Cooler Replacement (1.4L LUH, LUJ - AT) (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Service and Repair/Charge Air Cooler Replacement - AT). 6. Install the radiator. Refer to Radiator Replacement (LDE, LXV, 2H0, LUW - MT) (See: Radiator Replacement - MT)Radiator Replacement (LDE, LXV, 2H0, LUW - AT) (See: Radiator Replacement - AT)Radiator Replacement (1.4L LUH and LUJ - AT) (See: Radiator Replacement - AT)Radiator Replacement (1.4L LUH and LUJ - M32) (See: Radiator Replacement - MT). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the repair bolt (1) with locking compound and tighten to 5 Nm (45 lb in). Radiator Lower Bracket Replacement Radiator Lower Bracket Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 1892 Radiator Replacement - AT Radiator Replacement (1.4L LUH and LUJ - AT) Removal Procedure 1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 3. Drain coolant fluid. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Service and Repair/Cooling System Draining and Filling (GE-47716 Fill) ). 4. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Heating and Air Conditioning/Service and Repair/Procedures/Refrigerant Recovery and Recharging). 5. Remove the radiator outlet hose from the radiator. Refer to Radiator Outlet Hose Replacement (LDD, LUH, and LUJ) (See: Radiator Hose/Service and Repair/Radiator Outlet Hose Replacement)Radiator Outlet Hose Replacement (LDE, LXV, 2H0, and LUW) (See: Radiator Hose/Service and Repair/Radiator Outlet Hose Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 1893 6. Remove the radiator inlet hose from the radiator. Refer to Radiator Inlet Hose Replacement (LDD, LUH, and LUJ) (See: Radiator Hose/Service and Repair/Radiator Inlet Hose Replacement)Radiator Inlet Hose Replacement (LDE, LXV, 2H0, and LUW) (See: Radiator Hose/Service and Repair/Radiator Inlet Hose Replacement). 7. Remove the charge air cooler inlet air hose from the charge air cooler. Refer to Charge Air Cooler Inlet Air Hose Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Service and Repair/Charge Air Cooler Inlet Air Hose Replacement). 8. Remove the charge air cooler outlet air hose from the charge air cooler. Refer to Charge Air Cooler Outlet Air Hose Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair). 9. Remove the transmission fluid auxiliary cooler pipe. Refer to Transmission Fluid Cooler Hose/Pipe Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair/Transmission Fluid Cooler Hose/Pipe Replacement). 10. Remove the transmission fluid cooler inlet pipe from the radiator. Refer to Transmission Fluid Cooler Inlet Pipe Replacement (LDE, LUW) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair/Transmission Fluid Cooler Inlet Pipe Replacement)Transmission Fluid Cooler Inlet Pipe Replacement (LLU, LUJ) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair/Transmission Fluid Cooler Inlet Pipe Replacement). 11. Remove the transmission fluid cooler outlet pipe from the transmission fluid auxiliary cooler. Refer to Transmission Fluid Cooler Outlet Pipe Replacement (LDE, LUW) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair/Transmission Fluid Cooler Outlet Pipe Replacement)Transmission Fluid Cooler Outlet Pipe Replacement (LLU, LUJ) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair/Transmission Fluid Cooler Outlet Pipe Replacement). 12. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 13. Remove the air conditioning evaporator hose (3) from the condenser. 14. Disconnect the air conditioning refrigerant pressure sensor wiring harness plug (2). 15. Disconnect the engine coolant temperature sensor wiring harness plug (1). 16. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 1894 17. Remove the air conditioning compressor and condenser hose nut (1). 18. Remove the air conditioning compressor and condenser hose (2). 19. Unclip the engine coolant fan shroud from the radiator and hang it aside, using cable straps. 20. Secure the radiator assembly with 2 straps. 21. Remove the 4 radiator lower bracket bolts (1). 22. Remove the 2 lower radiator brackets (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 1895 Note: A second technician is required. Note: Do not remove the engine cooling fan shroud (1). 23. Remove the radiator assembly (2). 24. Remove the transmission fluid auxiliary cooler pipe bolt (3). 25. Unclip the 2 transmission fluid cooler pipes (2) from the transmission fluid cooler pipe bracket. 26. Unclip the transmission fluid cooler (1) from the radiator. 27. Unclip the transmission fluid cooler pipe bracket from the radiator. 28. Unclip the charge air cooler along with the AC condenser from the radiator. Installation Procedure 1. Clip the charge air cooler along with the AC condenser to the radiator. 2. Clip the transmission fluid cooler pipe bracket to the radiator. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 1896 3. Clip the transmission fluid cooler (1) to the radiator. 4. Clip the 2 transmission fluid cooler pipes (2) to the transmission fluid cooler pipe bracket. 5. Install the transmission fluid auxiliary cooler pipe bolt (3) and tighten. Note: A second technician is required. 6. Install the radiator assembly (2) and secure with 2 straps. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 1897 7. Install the 2 lower radiator brackets (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the 4 radiator lower bracket bolts (1) and tighten to 22 Nm (16 lb ft). 9. Clip in the engine coolant fan shroud to the radiator. 10. Install the air conditioning compressor and condenser hose (2). Use a NEW seal ring. Install the air conditioning compressor and condenser hose nut (1) and tighten to 19 Nm(14 lb ft). 11. Raise the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 1898 12. Install the air conditioning evaporator hose (3) to the condenser. Use a NEW seal ring. 13. Tighten the air conditioning evaporator hose nut to 19 Nm(14 lb ft). 14. Connect the air conditioning refrigerant pressure sensor wiring harness plug (2). 15. Connect the engine coolant temperature sensor wiring harness plug (1). 16. Lower the vehicle. 17. Install the radiator inlet hose to the radiator. Refer to Radiator Inlet Hose Replacement (LDD, LUH, and LUJ) (See: Radiator Hose/Service and Repair/Radiator Inlet Hose Replacement)Radiator Inlet Hose Replacement (LDE, LXV, 2H0, and LUW) (See: Radiator Hose/Service and Repair/Radiator Inlet Hose Replacement). 18. Install the radiator outlet hose to the radiator. Refer to Radiator Outlet Hose Replacement (LDD, LUH, and LUJ) (See: Radiator Hose/Service and Repair/Radiator Outlet Hose Replacement)Radiator Outlet Hose Replacement (LDE, LXV, 2H0, and LUW) (See: Radiator Hose/Service and Repair/Radiator Outlet Hose Replacement). 19. Install the charge air cooler inlet air hose to the charge air cooler. Refer to Charge Air Cooler Inlet Air Hose Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Service and Repair/Charge Air Cooler Inlet Air Hose Replacement). 20. Install the charge air cooler outlet air hose to the charge air cooler. Refer to Charge Air Cooler Outlet Air Hose Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair). 21. Install the transmission fluid cooler inlet pipe to the radiator. Refer to Transmission Fluid Cooler Inlet Pipe Replacement (LDE, LUW) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair/Transmission Fluid Cooler Inlet Pipe Replacement)Transmission Fluid Cooler Inlet Pipe Replacement (LLU, LUJ) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair/Transmission Fluid Cooler Inlet Pipe Replacement). 22. Install the transmission fluid cooler outlet pipe to the transmission fluid auxiliary cooler. Refer to Transmission Fluid Cooler Outlet Pipe Replacement (LDE, LUW) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair/Transmission Fluid Cooler Outlet Pipe Replacement)Transmission Fluid Cooler Outlet Pipe Replacement (LLU, LUJ) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair/Transmission Fluid Cooler Outlet Pipe Replacement). 23. Install the transmission fluid auxiliary cooler pipe. Refer to Transmission Fluid Cooler Hose/Pipe Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Line/Hose/Service and Repair/Transmission Fluid Cooler Hose/Pipe Replacement). 24. Fill up the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Heating and Air Conditioning/Service and Repair/Procedures/Refrigerant Recovery and Recharging). 25. Fill up coolant fluid. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Service and Repair/Cooling System Draining and Filling (GE-47716 Fill) ). 26. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 27. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Radiator Replacement - MT Radiator Replacement (1.4L LUH and LUJ - M32) Removal Procedure 1. Open the hood Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 1899 2. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 4. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Heating and Air Conditioning/Service and Repair/Procedures/Refrigerant Recovery and Recharging). 5. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). 6. Remove the radiator outlet hose from the radiator. Refer to Radiator Outlet Hose Replacement (LDD, LUH, and LUJ) (See: Radiator Hose/Service and Repair/Radiator Outlet Hose Replacement)Radiator Outlet Hose Replacement (LDE, LXV, 2H0, and LUW) (See: Radiator Hose/Service and Repair/Radiator Outlet Hose Replacement). 7. Remove the radiator inlet hose from the radiator. Refer to Radiator Inlet Hose Replacement (LDD, LUH, and LUJ) (See: Radiator Hose/Service and Repair/Radiator Inlet Hose Replacement)Radiator Inlet Hose Replacement (LDE, LXV, 2H0, and LUW) (See: Radiator Hose/Service and Repair/Radiator Inlet Hose Replacement). 8. Remove the charge air cooler inlet air hose from the charge air cooler. Refer to Charge Air Cooler Inlet Air Hose Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Service and Repair/Charge Air Cooler Inlet Air Hose Replacement). 9. Remove the charge air cooler outlet air hose from the charge air cooler. Refer to Charge Air Cooler Outlet Air Hose Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair). 10. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 11. Remove the air conditioning evaporator hose (3) from condenser. 12. Disconnect the air conditioning refrigerant pressure sensor wiring harness plug (2). 13. Disconnect the engine coolant temperature sensor wiring harness plug (1). 14. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 1900 15. Remove the air conditioning compressor and condenser hose nut (1). 16. Remove the air conditioning compressor and condenser hose (2). 17. Unclip the engine coolant fan shroud from the radiator and hang it aside, using cable straps. 18. Secure the radiator assembly with 2 straps. 19. Remove the 4 lower radiator bracket bolts (2). 20. Remove the 2 lower radiator brackets (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 1901 Note: A second technician is required. Note: Do not remove the engine cooling fan shroud (1). 21. Remove the 2 straps. 22. Remove the radiator assembly (2). 23. Unclip the radiator from the charge air cooler and the condenser. Installation Procedure 1. Install the radiator to the condenser and the charge air cooler. Note: A second technician is required. 2. Install the radiator assembly (2) and secure it with 2 straps. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 1902 3. Install the 2 lower radiator brackets (1) Caution: Refer to. 4. Install the 4 lower radiator bracket bolts (2) and tighten to 22 Nm (16 lb ft). 5. Clip in the engine coolant fan shroud to the radiator. 6. Install the air conditioning compressor and condenser hose (1). Use a NEW seal ring. Install the air conditioning compressor and condenser hose nut (2) and tighten to 19 Nm (14 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 1903 7. Install the air conditioning evaporator hose (3) to the condenser. Use a NEW seal ring. 8. Tighten the air conditioning evaporator hose nut to 19 Nm (14 lb ft). 9. Connect the air conditioning refrigerant pressure sensor wiring harness plug (2). 10. Connect the engine coolant temperature sensor wiring harness plug (1). 11. Lower the vehicle. 12. Install the radiator inlet hose to the radiator. Refer to Charge Air Cooler Inlet Air Hose Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Service and Repair/Charge Air Cooler Inlet Air Hose Replacement). 13. Install the radiator outlet hose to the radiator. Refer to Charge Air Cooler Outlet Air Hose Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair). 14. Install the radiator inlet hose to the radiator. Refer to Radiator Inlet Hose Replacement (LDD, LUH, and LUJ) (See: Radiator Hose/Service and Repair/Radiator Inlet Hose Replacement)Radiator Inlet Hose Replacement (LDE, LXV, 2H0, and LUW) (See: Radiator Hose/Service and Repair/Radiator Inlet Hose Replacement). 15. Install the radiator outlet hose to the radiator. Refer to Radiator Outlet Hose Replacement (LDD, LUH, and LUJ) (See: Radiator Hose/Service and Repair/Radiator Outlet Hose Replacement)Radiator Outlet Hose Replacement (LDE, LXV, 2H0, and LUW) (See: Radiator Hose/Service and Repair/Radiator Outlet Hose Replacement). 16. Top up the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Heating and Air Conditioning/Service and Repair/Procedures/Refrigerant Recovery and Recharging). 17. If the headlamp was removed. Refer to Headlamp Replacement (See: Lighting and Horns/Headlamp/Service and Repair). 18. Top up the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). 19. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 20. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Radiator Support Bracket Replacement Radiator Support Bracket Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 1904 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement Radiator Hose: Service and Repair Radiator Inlet Hose Replacement Radiator Inlet Hose Replacement (LDD, LUH, and LUJ) (1.4L) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 1909 Radiator Hose: Service and Repair Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement (LDD, LUH, and LUJ) (1.4L) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1914 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1915 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1916 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Service and Repair Coolant Level Sensor: Service and Repair Engine Coolant Level Indicator Module Replacement (LDD, LUH, LUJ, LDE, LLU, LUW) (1.4L, 1.8L) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Powertrain Component Views Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Powertrain Component Views Engine Components - Left Rear (LUJ) 1 - B111 Turbocharger Boost Pressure Sensor 2 - T8 Ignition Coil 3 - B68 Knock Sensor (KS) 4 Q38 Throttle Body 5 - B34 Engine Coolant Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Powertrain Component Views > Page 1926 Coolant Temperature Sensor/Switch (For Computer): Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components 1 - G105 Engine Compartment - Front Left 2 - G10 Cooling Fan Motor 3 - B34B Engine Coolant Temperature Sensor 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Engine Coolant Temperature Sensor Replacement (Radiator) Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement (Radiator) Engine Coolant Temperature Sensor Replacement (Radiator) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Engine Coolant Temperature Sensor Replacement (Radiator) > Page 1929 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement (Water Outlet) Engine Coolant Temperature Sensor Replacement (Water Outlet) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Recalls for Thermostat: > 10399A > Dec > 10 > Campaign Thermostat Sticks Open Causes Shift Issues Thermostat: Recalls Campaign - Thermostat Sticks Open Causes Shift Issues SERVICE UPDATE Bulletin No.: 10399A Date: December 02, 2010 Subject: 10399A - Service Update for Inventory and Customer Vehicles - Powertrain Improvements - Thermostat Sticks in Open Position and Shift Quality - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with a 1.4L Turbo Engine (LUJ) Supercede: The Subject and Purpose in this bulletin are being revised to advise that the new ECM calibration will also address shift quality issues.Please discard all copies of bulletin 10399, issued November 2010. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to reprogram the engine control module (ECM) on certain 2011 model year Chevrolet Cruze vehicles equipped with a 1.4L turbo engine (LUJ). These vehicles may have a condition where the thermostat sticks in the open position. If this occurs, diagnostic codes will be set and the Service Vehicle Soon light/message will illuminate. These vehicles may also have transmission shift quality issues due to calibration values. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. Additionally, a list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should also be checked for vehicle eligibility. Parts Information No parts are required for this update. Service Procedure Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 11/29/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming. 2. Reprogram the engine control module (ECM) and transmission control module (TCM) in sequence. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI or Tech 2(R) to the vehicle. If using MDI, connect to programming terminal with the cable (USB or LAN). 2. Select J-2534 MDI or J-2534 Tech 2(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Recalls for Thermostat: > 10399A > Dec > 10 > Campaign Thermostat Sticks Open Causes Shift Issues > Page 1938 3. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. 4. Follow the on-screen instructions. 3. Clear all DTCs using the GDS or Tech 2(R). Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues Thermostat: All Technical Service Bulletins Campaign - Thermostat Sticks Open Causes Shift Issues SERVICE UPDATE Bulletin No.: 10399A Date: December 02, 2010 Subject: 10399A - Service Update for Inventory and Customer Vehicles - Powertrain Improvements - Thermostat Sticks in Open Position and Shift Quality - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with a 1.4L Turbo Engine (LUJ) Supercede: The Subject and Purpose in this bulletin are being revised to advise that the new ECM calibration will also address shift quality issues.Please discard all copies of bulletin 10399, issued November 2010. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to reprogram the engine control module (ECM) on certain 2011 model year Chevrolet Cruze vehicles equipped with a 1.4L turbo engine (LUJ). These vehicles may have a condition where the thermostat sticks in the open position. If this occurs, diagnostic codes will be set and the Service Vehicle Soon light/message will illuminate. These vehicles may also have transmission shift quality issues due to calibration values. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. Additionally, a list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should also be checked for vehicle eligibility. Parts Information No parts are required for this update. Service Procedure Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 11/29/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming. 2. Reprogram the engine control module (ECM) and transmission control module (TCM) in sequence. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI or Tech 2(R) to the vehicle. If using MDI, connect to programming terminal with the cable (USB or LAN). 2. Select J-2534 MDI or J-2534 Tech 2(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues > Page 1944 3. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. 4. Follow the on-screen instructions. 3. Clear all DTCs using the GDS or Tech 2(R). Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair Thermostat Housing: Service and Repair Engine Coolant Thermostat Housing Replacement (1.4L LUH and LUJ) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (1.4L LUH and LUJ) (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 3. Disconnect the positive crankcase ventilation pipe from the turbocharger. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement ( See: Powertrain Management/Emission Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair). 4. Remove the radiator outlet hose from the engine coolant thermostat housing. Refer to Radiator Outlet Hose Replacement (LDD, LUH, and LUJ) ( See: Radiator Hose/Service and Repair/Radiator Outlet Hose Replacement)Radiator Outlet Hose Replacement (LDE, LXV, 2H0, and LUW) ( See: Radiator Hose/Service and Repair/Radiator Outlet Hose Replacement). 5. Disconnect the engine coolant temperature sensor wiring harness connector. 6. Remove the engine oil cooler outlet hose clamp (2). 7. Remove the engine oil cooler outlet hose (3) from the engine coolant thermostat housing. 8. Remove the 3 engine coolant thermostat housing bolts (4). 9. Remove the engine coolant thermostat housing (5) and the seal ring (1). Installation Procedure 1. Clean the sealing surfaces. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair > Page 1948 2. Install the engine coolant thermostat housing (5) along with a NEW seal ring (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 3 engine coolant thermostat housing bolts (4) and tighten to 8 Nm(71 lb in). 4. Install the engine oil cooler outlet hose (3) to the engine coolant thermostat housing. 5. Install the engine oil cooler outlet hose clamp (2). 6. Connect the engine coolant temperature sensor wiring harness connector. 7. Install the radiator outlet hose to the engine coolant thermostat housing. Refer to Radiator Outlet Hose Replacement (LDD, LUH, and LUJ) (See: Radiator Hose/Service and Repair/Radiator Outlet Hose Replacement)Radiator Outlet Hose Replacement (LDE, LXV, 2H0, and LUW) (See: Radiator Hose/Service and Repair/Radiator Outlet Hose Replacement). 8. Connect the positive crankcase ventilation pipe to the turbocharger. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (See: Powertrain Management/Emission Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair). 9. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (1.4L LUH and LUJ) (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 10. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Service and Repair/Cooling System Draining and Filling (GE-47716 Fill) ). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Turbocharger Coolant Line > Component Information > Service and Repair > Turbocharger Coolant Feed Pipe Replacement Turbocharger Coolant Line: Service and Repair Turbocharger Coolant Feed Pipe Replacement Turbocharger Coolant Feed Pipe Replacement (1.4L LUH and LUJ) Removal Procedure 1. Remove the turbocharger. Refer to Turbocharger Replacement (See: Service and Repair). 2. Remove the turbocharger coolant feed pipe from quick fitting connector. Refer to Turbocharger Disassemble (See: Engine, Cooling and Exhaust/Engine/Service and Repair/Overhaul/54. Turbocharger Disassemble). Installation Procedure 1. Install the turbocharger coolant feed pipe to the quick fitting connector. Refer to Turbocharger Assemble (See: Engine, Cooling and Exhaust/Engine/Service and Repair/Overhaul/56. Turbocharger Assemble). 2. Install the turbocharger. Refer to Turbocharger Replacement (See: Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Turbocharger Coolant Line > Component Information > Service and Repair > Turbocharger Coolant Feed Pipe Replacement > Page 1953 Turbocharger Coolant Line: Service and Repair Turbocharger Coolant Return Pipe Replacement Turbocharger Coolant Return Pipe Replacement (1.4L LUH and LUJ) Removal Procedure 1. Remove the turbocharger. Refer to Turbocharger Replacement (See: Service and Repair). 2. Remove the turbocharger coolant return pipe from quick fitting connector. Refer to Turbocharger Disassemble (See: Engine, Cooling and Exhaust/Engine/Service and Repair/Overhaul/54. Turbocharger Disassemble). 3. Replace the quick fitting connector. Refer to Turbocharger Disassemble (See: Engine, Cooling and Exhaust/Engine/Service and Repair/Overhaul/54. Turbocharger Disassemble). Installation Procedure 1. Install the turbocharger coolant return pipe to the quick fitting connector. Refer to Turbocharger Disassemble (See: Engine, Cooling and Exhaust/Engine/Service and Repair/Overhaul/54. Turbocharger Disassemble). 2. Install the turbocharger. Refer to Turbocharger Replacement (See: Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Drive Pulley, Water Pump > Component Information > Service and Repair Drive Pulley: Service and Repair Water Pump Pulley Replacement (LDD, LUH, and LUJ) (1.4L) Removal Procedure 1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.4L LUH and LUJ) (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 2. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side (See: Engine/Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Removal and Replacement/Engine Mount Bracket Replacement - Right Side). 3. Remove the drive belt. Refer to Drive Belt Replacement (See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 4. Loosen the 3 water pump pulley bolts (2) while holding the water pump pulley hub with a wrench. 5. Remove the 3 water pump pulley bolts (2). 6. Remove the water pump pulley (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Drive Pulley, Water Pump > Component Information > Service and Repair > Page 1958 1. Install the water pump pulley (1). 2. Install the 3 water pump pulley bolts (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the 3 water pump pulley bolts to 22 Nm (16 lb ft) while holding the water pump pulley hub with a wrench. 4. Install the drive belt. Refer to Drive Belt Replacement (See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair ). 5. Install the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side (See: Engine/Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Removal and Replacement/Engine Mount Bracket Replacement - Right Side). 6. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.4L LUH and LUJ) (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Service and Repair Catalyst Shield: Service and Repair Catalytic Converter Heat Shield Replacement (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair Exhaust Pipe: Service and Repair Exhaust Front Pipe Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 1967 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair Exhaust Pipe/Muffler Hanger: Service and Repair Exhaust Pipe Front Hanger Bracket Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement Heat Shield: Service and Repair Exhaust Manifold Heat Shield Replacement Exhaust Manifold Heat Shield Replacement (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement > Page 1975 Heat Shield: Service and Repair Exhaust Heat Shield Replacement Exhaust Heat Shield Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement > Page 1976 Heat Shield: Service and Repair Exhaust Rear Muffler Heat Shield Replacement Exhaust Rear Muffler Heat Shield Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement > Page 1977 Heat Shield: Service and Repair Fuel Tank Heat Shield Replacement (Gasoline) Fuel Tank Heat Shield Replacement (Gasoline) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement > Page 1978 Heat Shield: Service and Repair Warm Up Three-Way Catalytic Converter Replacement Warm Up Three-Way Catalytic Converter Replacement (1.4L LUH and LUJ) Removal Procedure 1. Open the hood. 2. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Disconnect the heated oxygen sensor 1 wiring harness connector. Refer to Heated Oxygen Sensor Replacement - Sensor 1 (1.4L LUH and LUJ) ( See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Heated Oxygen Sensor Replacement - Sensor 1 ). 4. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (1.4L LUH and LUJ) (See: Exhaust Manifold Heat Shield Replacement)Exhaust Manifold Heat Shield Replacement (1.6L LDE, LXV, 1.8L 2H0, and LUW) (See: Exhaust Manifold Heat Shield Replacement). 5. Loosen the three way warm up catalytic converter V-clamp bolt (2) so that the three way warm up catalytic converter V-clamp (1) can be removed from catalytic converter to turbocharger flange. 6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement > Page 1979 Warning Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury. Caution: Do not bend the exhaust flex pipe more than 10 degrees in any direction. Bending of more than 10 degrees or twisting in a range of ±0.5 degrees will damage the exhaust flex decoupler. 7. Remove the 3 catalytic converter flange nuts (2). 8. Remove the catalytic converter (3) from the three way warm up catalytic converter and hang aside. 9. Remove the catalytic converter gasket (1). 10. Remove the 2 three way warm up catalytic converter bracket nuts (1) and (2). 11. Remove the three way warm up catalytic converter and the three way warm up catalytic converter to turbocharger seal ring. 12. Remove the heated oxygen sensor 1 from the three way warm up catalytic converter. Refer to Heated Oxygen Sensor Replacement - Sensor 1 (1.4L LUH and LUJ) (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Heated Oxygen Sensor Replacement - Sensor 1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement > Page 1980 1. Install the heated oxygen sensor 1 to the three way warm up catalytic converter. Refer to Heated Oxygen Sensor Replacement - Sensor 1 (1.4L LUH and LUJ) (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Heated Oxygen Sensor Replacement - Sensor 1). Note: Never re-use the V-clamp. 2. Pre-install a NEW three way warm up catalytic converter V-clamp. 3. Install the three way warm up catalytic converter to the turbocharger and the three way warm up catalytic converter brackets. Install a NEW three way warm up catalytic converter to turbocharger seal ring. 4. Install and hand-tighten the 2 three way warm up catalytic converter bracket nuts (1) and (2). 5. Lower the vehicle. 6. Install the three way warm up catalytic converter V-clamp to the catalytic converter to turbocharger flange. 7. The three way warm up catalytic converter V-clamp (1) should be installed in the shown position. 8. Hand-tighten the three way warm up catalytic converter V-clamp. 9. Raise and support the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement > Page 1981 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 10. Tighten the 2 three way catalytic converter bracket nuts to 22 Nm (16 lb ft). 11. Install the catalytic converter (3) and a NEW catalytic converter gasket (1) to the three way warm up catalytic converter. 12. Install the 3 catalytic converter flange nuts (2) and tighten to 22 Nm (16 lb ft). 13. Lower the vehicle. 14. Tighten the three way catalytic converter V-clamp bolt to 13 Nm (115 lb in). 15. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (1.4L LUH and LUJ) (See: Exhaust Manifold Heat Shield Replacement)Exhaust Manifold Heat Shield Replacement (1.6L LDE, LXV, 1.8L 2H0, and LUW) (See: Exhaust Manifold Heat Shield Replacement). 16. Connect the heated oxygen sensor 1 wiring harness plug. Refer to Heated Oxygen Sensor Replacement - Sensor 1 (1.4L LUH and LUJ) (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Heated Oxygen Sensor Replacement - Sensor 1). 17. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 18. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair Exhaust Rear Muffler Replacement Removal Procedure Warning: Refer to Exhaust Service Warning (See: Service Precautions). Warning: Refer to Protective Goggles and Glove Warning (See: Service Precautions/Technician Safety Information/Protective Goggles and Glove Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the 2 exhaust rear muffler hanger insulators (3) from the exhaust rear muffler (4). 3. Remove the exhaust rear muffler end pipe bracket bolt (1) from the exhaust rear muffler end pipe bracket (2). 4. Remove the exhaust rear muffler end pipe bracket (2). Note: Support the exhaust rear muffler with a jack. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 1985 Note: The follow step is only necessary if the new exhaust rear muffler is not equipped with the exhaust rear muffler end pipe. 5. Cut the exhaust rear muffler at position (2) and remove the exhaust rear muffler end pipe. 6. Cut the exhaust rear muffler at position (1). 7. Remove the exhaust rear muffler. Installation Procedure 1. Install the exhaust rear muffler (6) and hang in the 2 exhaust rear muffler hanger insulators (5). 2. Install the exhaust pipe clamp (1) and loosely tighten. 3. Install the exhaust rear muffler end pipe bracket (3) to the exhaust rear muffler end pipe. Note: The follow step is only necessary if the new exhaust rear muffler is not equipped with the exhaust rear muffler end pipe. 4. Install the exhaust rear muffler end pipe. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the exhaust rear muffler end pipe bracket bolt (4) to the exhaust rear muffler end pipe bracket (3) and tighten to 22 Nm (16 lb ft). 6. Install the exhaust pipe clamp (2) and loosely tighten. 7. Position the exhaust rear muffler. 8. Tighten the exhaust pipe clamp (1) to 20 Nm (15 lb ft). 9. Position the exhaust rear muffler end pipe. 10. Tighten the exhaust pipe clamp (2) to 20 Nm (15 lb ft). 11. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Recalls for Body Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Body Control Module: Recalls Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Recalls for Body Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 1997 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Recalls for Body Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 1998 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Body Control Module: All Technical Service Bulletins Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 2004 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 2005 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2006 Body Control Module: Locations Instrument Panel/Center Console Component Views Behind the Center of the I/P Components 1 of 4 1 - K9 Body Control Module 2 - X7 Body Control Module X7 3 - X6 Body Control Module X6 4 - X5 Body Control Module X5 5 - X4 Body Control Module X4 6 - X3 Body Control Module X3 7 - X2 Body Control Module X2 8 - X1 Body Control Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2007 Body Control Module: Diagrams Component Connector End Views K9 Body Control Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2008 K9 Body Control Module X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2009 K9 Body Control Module X3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2010 K9 Body Control Module X4 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2011 K9 Body Control Module X5 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2012 K9 Body Control Module X6 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2013 K9 Body Control Module X7 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2014 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Body Control Module Replacement Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Body Control Module Replacement > Page 2017 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues Engine Control Module: Recalls Campaign - Thermostat Sticks Open Causes Shift Issues SERVICE UPDATE Bulletin No.: 10399A Date: December 02, 2010 Subject: 10399A - Service Update for Inventory and Customer Vehicles - Powertrain Improvements - Thermostat Sticks in Open Position and Shift Quality - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with a 1.4L Turbo Engine (LUJ) Supercede: The Subject and Purpose in this bulletin are being revised to advise that the new ECM calibration will also address shift quality issues.Please discard all copies of bulletin 10399, issued November 2010. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to reprogram the engine control module (ECM) on certain 2011 model year Chevrolet Cruze vehicles equipped with a 1.4L turbo engine (LUJ). These vehicles may have a condition where the thermostat sticks in the open position. If this occurs, diagnostic codes will be set and the Service Vehicle Soon light/message will illuminate. These vehicles may also have transmission shift quality issues due to calibration values. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. Additionally, a list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should also be checked for vehicle eligibility. Parts Information No parts are required for this update. Service Procedure Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 11/29/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming. 2. Reprogram the engine control module (ECM) and transmission control module (TCM) in sequence. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI or Tech 2(R) to the vehicle. If using MDI, connect to programming terminal with the cable (USB or LAN). 2. Select J-2534 MDI or J-2534 Tech 2(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues > Page 2026 3. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. 4. Follow the on-screen instructions. 3. Clear all DTCs using the GDS or Tech 2(R). Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Engine Control Module: Recalls Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 2031 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 2032 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues Engine Control Module: All Technical Service Bulletins Campaign - Thermostat Sticks Open Causes Shift Issues SERVICE UPDATE Bulletin No.: 10399A Date: December 02, 2010 Subject: 10399A - Service Update for Inventory and Customer Vehicles - Powertrain Improvements - Thermostat Sticks in Open Position and Shift Quality - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with a 1.4L Turbo Engine (LUJ) Supercede: The Subject and Purpose in this bulletin are being revised to advise that the new ECM calibration will also address shift quality issues.Please discard all copies of bulletin 10399, issued November 2010. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to reprogram the engine control module (ECM) on certain 2011 model year Chevrolet Cruze vehicles equipped with a 1.4L turbo engine (LUJ). These vehicles may have a condition where the thermostat sticks in the open position. If this occurs, diagnostic codes will be set and the Service Vehicle Soon light/message will illuminate. These vehicles may also have transmission shift quality issues due to calibration values. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. Additionally, a list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should also be checked for vehicle eligibility. Parts Information No parts are required for this update. Service Procedure Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 11/29/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming. 2. Reprogram the engine control module (ECM) and transmission control module (TCM) in sequence. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI or Tech 2(R) to the vehicle. If using MDI, connect to programming terminal with the cable (USB or LAN). 2. Select J-2534 MDI or J-2534 Tech 2(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues > Page 2038 3. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. 4. Follow the on-screen instructions. 3. Clear all DTCs using the GDS or Tech 2(R). Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 2043 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Engine Control Module: All Technical Service Bulletins Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 2048 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 2049 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 2054 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 2055 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 2056 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 2062 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 2067 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 2068 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission Aftermarket Calibrations > Page 2069 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2070 Engine Control Module: Description and Operation Engine Control Module Description The engine control module (ECM) interacts with many emission related components and systems, and monitors the emission related components and systems for deterioration. OBD II diagnostics monitor the system performance and a diagnostic trouble code (DTC) sets if the system performance degrades. The malfunction indicator lamp (MIL) operation and the DTC storage are dictated by the DTC type. A DTC is ranked as a type A or type B if the DTC is emissions related. Type C is a non emissions related DTC. The ECM is located in the engine compartment. The ECM is the control center of the engine controls system. The ECM controls the following components: * The fuel injection system * The ignition system * The emission control systems * The on-board diagnostics * The A/C and fan systems * The throttle body motor system The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect the vehicle performance and the emissions. The ECM also performs diagnostic tests on various parts of the system. The ECM can recognize operational conditions and alert the driver via the MIL. When the ECM detects a malfunction, the ECM stores a DTC. The condition area is identified by the particular DTC that is set. This helps the technician in making repairs. ECM Function The engine control module (ECM) can supply 5 V or 12 V to the various sensors or switches. This is done through pull-up resistors to the regulated power supplies within the ECM. In some cases, even an ordinary shop voltmeter will not give an accurate reading because the resistance is too low. Therefore, a DMM with at least 10 Mohm input impedance is required in order to ensure accurate voltage readings. The ECM controls the output circuits by controlling the ground or the power feed circuit through the transistors or a device called an output driver module. EEPROM The programmable read only memory (EEPROM), which can be erased electronically, is a permanent memory that is physically part of the engine control module (ECM). The EEPROM contains program and calibration information that the ECM needs in order to control the powertrain operation. Special equipment, as well as the correct program and calibration for the vehicle, are required in order to reprogram the ECM. ECM Default Actions When a malfunction occurs within the engine control system, the engine control module (ECM) maintains control of the system with default actions. Default actions are calculated values, and/or calibrated default values, that are stored within the ECM. A certain level of engine performance is possible when a malfunction occurs dependant on the default actions taken. The ECM default actions prevent a complete loss of engine performance. ECM Output Controls The scan tool can control certain solenoids, valves, motors, and relays. The output controls can be found under the special functions selection of the scan tool. Some output controls may be disabled by the engine control module (ECM) during certain types of vehicle operation. Data Link Connector (DLC) The data link connector (DLC) is a 16-pin connector that provides the technician with a means of accessing serial data for aid in the diagnosis. This connector allows the technician to use a scan tool in order to monitor the various serial data parameters, and display the DTC information. The DLC is located inside the drivers compartment, underneath the dash. Malfunction Indicator Lamp (MIL) The malfunction indicator lamp (MIL) is located on the instrument panel cluster, or the driver information center. The MIL is controlled by the engine control module (ECM) and illuminates when the ECM detects a condition that affects the vehicle emissions. ECM Service Precautions Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2071 The engine control module (ECM), by design, can withstand the normal current draws that are associated with the vehicle operations. However, care must be taken in order to avoid overloading any of these circuits. When testing for opens or shorts, do not ground or apply voltage to any of the ECM circuits unless the diagnostic procedure instructs you to do so. These circuits should only be tested with a DMM. Aftermarket (Add-On) Electrical And Vacuum Equipment Caution: Do not attach add-on vacuum operated equipment to this vehicle. The use of add-on vacuum equipment may result in damage to vehicle components or systems. Caution: Connect any add-on electrically operated equipment to the vehicle's electrical system at the battery (power and ground) in order to prevent damage to the vehicle. Aftermarket, add-on, electrical and vacuum equipment is defined as any equipment installed on a vehicle after leaving the factory that connects to the vehicles electrical or vacuum systems. No allowances have been made in the vehicle design for this type of equipment. Add-on electrical equipment, even when installed to these strict guidelines, may still cause the powertrain system to malfunction. This may also include equipment not connected to the vehicle electrical system, such as portable telephones and radios. Therefore, the first step in diagnosing any powertrain condition is to make sure all of the after-market electrical equipment is removed or disconnected from the vehicle. After this has been done and if the condition still exists, the condition may be diagnosed in the normal manner. Electrostatic Discharge (ESD) Damage Note: In order to prevent possible electrostatic discharge damage to the ECM, do not touch the connector pins on the ECM. The electronic components that are used in the control systems are often designed to carry very low voltage. The electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 V of static electricity can cause damage to some electronic components. By comparison, it takes as much as 4 000 V for a person to even feel the zap of a static discharge. There are several ways for a person to become statically charged. The most common methods of charging are by friction and by induction. An example of charging by friction is a person sliding across a car seat. Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground. Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage, therefore, it is important to exercise great care when handling and testing electronic components. Emission Control Information Label The underhood vehicle emissions control information label contains important emission specifications and setting procedures. This identifies the year, the manufacturing division of the engine, the displacement of the engine in liters, the class of the vehicle, and type of fuel metering system. There is also an illustrated emission components and vacuum hose schematic. This label is located in the engine compartment of every General Motors vehicle. If the label has been removed, it can be ordered from GM service parts operations (GMSPO). Underhood Inspection Note: This inspection is very important and must be done carefully and thoroughly. Perform a careful underhood inspection when performing any diagnostic procedure or diagnosing the cause of an emission test failure. This can often lead to repairing a condition without further steps. Use the following guidelines when performing an inspection: * Inspect all of the vacuum hoses for correct routing, pinches, cuts, or disconnects. * Inspect any hoses that are difficult to see. * Inspect all of the wires in the engine compartment for the following conditions: - Burned or chafed spots - Pinched wires - Contact with sharp edges - Contact with hot exhaust manifolds Basic Knowledge Required Caution: Lack of basic knowledge of this powertrain when performing diagnostic procedures could result in incorrect diagnostic performance or damage to powertrain components. Do not attempt to diagnose a powertrain problem without this basic knowledge. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2072 A basic understanding of hand tools is necessary in order to effectively use this section of the service manual. You must be familiar with some of the basics of engine operation and electrical diagnosis in order to use this section of the service manual. * Basic electrical circuits, You should have an understanding of basic electricity and know the meaning of voltage (V), current (A), and resistance (ohm). You should understand what happens in a circuit with an open or a shorted wire, and you should be able to identify a shorted or open circuit by using a digital multimeter (DMM). You should be able to read and understand a wiring diagram. * Use of digital multimeter, You should be familiar with the DMM, particularly the essential tool. You should be able to use the meter in order to measure the voltage (V), the resistance (ohm), the current (A), intermittent (minimum/maximum), and frequency (Hz). * Use of circuit testing tools, You should not use a test lamp to diagnose the engine controls system unless you are specifically instructed to do so. You should know how to use jumper wires in order to test the components and allow DMM readings without damaging the terminals. You should know how to use the J 35616 - Adapter Kit and use the kit whenever the diagnostic procedures call for front probing any connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2073 Engine Control Module: Service and Repair Engine Control Module Replacement Removal Procedure Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note: It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last engine oil change. 1. Prepare the engine control module for the replacement. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). 2. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 3. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 4. Disconnect the 2 wiring harness plug (2) from the engine control module (3). 5. Unclip the engine control module bracket (4) from the battery tray. 6. Remove the 4 nuts (1). 7. Remove the engine control module (3) from the engine control module bracket (4). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2074 1. Install the engine control module (3) to the engine control module bracket (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 4 nuts (1) and tighten to 9 Nm (80 lb in). 3. Clip the engine control module bracket (4) to the battery tray. 4. Connect the 2 wiring harness plug (2) to the engine control module (3). 5. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 6. Program the ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood Main Relay (Computer/Fuel System): Locations Fuse Block - Underhood Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 2079 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 2080 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 2081 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 2082 Main Relay (Computer/Fuel System): Locations Fuse Block - Instrument Panel Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 2083 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2088 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2089 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2090 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood Main Relay (Computer/Fuel System): Locations Fuse Block - Underhood Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 2095 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 2096 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 2097 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 2098 Main Relay (Computer/Fuel System): Locations Fuse Block - Instrument Panel Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 2099 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations Ignition Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 2104 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 2105 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 2106 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 2107 Ignition Relay: Testing and Inspection Ignition Relay Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description The powertrain relay, is controlled by the engine control module (ECM) depending upon input from the ignition switch. Battery positive voltage is supplied to the relay coil and switch. When the ignition switch is turned to the ON position, the ECM will provide ground on the control circuit of the relay using a low side driver. This will allow voltage through the relay switch contacts to the components. The ECM monitors the voltage level on the control circuit of the relay. Diagnostic Aids The relay electrical contacts may be pitted or sticking. Replace the powertrain relay , if gently tapping or wiggling the powertrain relay causes a change in the relays operation. Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) DTC Type Reference Powertrain Diagnostic Trouble Code (DTC) Type Definitions (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Powertrain Diagnostic Trouble Code (DTC) Type Definitions) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Special Tools EL 43244 - Relay Puller Pliers For equivalent regional tools, refer to Special Tools (See: Computers and Control Systems/Tools and Equipment). Circuit/System Verification Warning An electric fan under the hood can start up even when the engine is not running and can injure you. Keep hands, clothing and tools away from any underhood electric fan. 1. Cycle the ignition from OFF to ON. You should hear and feel an audible click from the KR75 Powertrain Relay. Repeat as necessary in order to verify KR75 Powertrain Relay operation. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 2108 2. Operate the vehicle within the Conditions for running the DTC to verify the DTC does not reset. You may also operate the vehicle within the conditions that you observed from the freeze frame/failure records data. Circuit/System Testing 1. Ignition OFF, disconnect the KR75 Powertrain Relay. 2. Ignition ON, verify a test lamp illuminates between the KR75 Powertrain Relay coil ignition voltage circuit terminal 85 and ground. ‹› If the test lamp does not illuminate, repair the KR75 Powertrain Relay coil ignition voltage circuit for a short to ground or an open/high resistance. Replace the fuse if necessary. 3. Ignition OFF, connect a test lamp between the KR75 Powertrain Relay coil control circuit terminal 86 and the KR75 Powertrain Relay coil ignition voltage circuit terminal 85. ‹› If the test lamp is always ON, test the KR75 Powertrain Relay control circuit for a short to ground. If the circuit tests normal, replace the K20 Engine Control Module. 4. Ignition ON. The test lamp should turn ON. ‹› If the test lamp is always OFF, test the KR75 Powertrain Relay ECM control circuit for a short to voltage or an open/high resistance. If circuit tests normal, replace the K20 Engine Control Module. Note: The ignition voltage circuit is between the KR75 Powertrain Relay and the ECM. The ignition voltage is a feedback circuit. 5. Install a 20 A fused jumper wire between the KR75 Powertrain Relay switch B+ circuit terminal 30 and the KR75 Powertrain Relay switch ignition voltage circuit terminal 87. 6. Attempt to start the engine. The engine should start. ‹› If the engine does not start, test the ignition voltage circuit between the KR75 Powertrain Relay and the K20 Engine Control Module for a short to ground or for an open/high resistance. If the circuit tests normal, replace the K20 Engine Control Module. 7. If all circuits test normal, test or replace the KR75 Powertrain Relay. Component Testing Relay Test 1. Ignition OFF, remove the KR75 Powertrain Relay from the electrical center with the EL 43244 Relay Puller Pliers. 2. Test for 70-110 ohm between terminals 85 and 86. ‹› If not within the specified range, replace the KR75 Powertrain Relay. 3. Test for infinite resistance between the following terminals: * 30 and 86 * 30 and 87 * 30 and 85 * 85 and 87 ‹› If not the specified value, replace the KR75 Powertrain Relay. 4. Install a 20 A fused jumper wire between KR75 Powertrain Relay terminal 85 and 12 V. Install a jumper wire between KR75 Powertrain Relay terminal 86 and ground. Test for less than 2 ohm between terminals 30 and 87. ‹› If greater than the specified range, replace the KR75 Powertrain Relay. Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) * Control Module References (See: Testing and Inspection/Programming and Relearning)for ECM replacement, setup, and programming Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2114 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views B107 Accelerator Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2115 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Right Front of the Vehicle Components 1 of 2 1 - B75B Mass Air Flow/Intake Air Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2119 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor Replacement (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations Barometric Pressure Sensor: Locations Powertrain Component Views Engine Components - Right Rear (LUJ) 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Locations Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Side of the Engine Compartment Components 2 of 2 1 - B18 Battery Current Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Locations > Page 2126 Battery Current Sensor: Diagrams Component Connector End Views B18 Battery Current Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Locations > Page 2127 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Open the hood. 2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Remove the battery ground cable nut (1). 4. Remove the battery negative cable (2). 5. Disconnect the wiring harness current sensor plug (4). 6. Remove the current sensor (5) from the battery tray. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Locations > Page 2128 7. Remove the current sensor (2) from the battery negative cable (1). Installation Procedure 1. Install the current sensor (2) to the battery negative cable (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Locations > Page 2129 2. Install the current sensor (5) to the battery tray. 3. Connect the wiring harness current sensor plug (4). 4. Install the battery negative cable (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the battery ground cable nut (1) and tighten to 9 Nm (80 lb in). 6. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 7. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Powertrain Component Views Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Powertrain Component Views Engine Components - Left Rear (LUJ) 1 - B111 Turbocharger Boost Pressure Sensor 2 - T8 Ignition Coil 3 - B68 Knock Sensor (KS) 4 Q38 Throttle Body 5 - B34 Engine Coolant Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Powertrain Component Views > Page 2134 Coolant Temperature Sensor/Switch (For Computer): Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components 1 - G105 Engine Compartment - Front Left 2 - G10 Cooling Fan Motor 3 - B34B Engine Coolant Temperature Sensor 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Engine Coolant Temperature Sensor Replacement (Radiator) Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement (Radiator) Engine Coolant Temperature Sensor Replacement (Radiator) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Engine Coolant Temperature Sensor Replacement (Radiator) > Page 2137 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement (Water Outlet) Engine Coolant Temperature Sensor Replacement (Water Outlet) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views Crankshaft Position Sensor: Locations Disassembled Views Disassembled Views Engine Block Assembly - 1.4L LDD 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Engine Block 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2142 16 - Oil Pan Bolt 17 - Oil Pan Drain Plug Seal Ring 18 - Oil Pan Drain Plug 19 - Crankshaft Position Sensor Bolt 20 - Crankshaft Position Sensor 21 - Crankshaft Position Sensor Seal Ring 22 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 23 - Crankshaft Position Sensor Reluctor Ring 24 Flywheel Bolt 25 - Engine Flywheel 26 - Crankshaft Rear Oil Seal 27 - Crankshaft Position Sensor Reluctor Ring Bolt 28 - Connecting Rod Bearing Cap Bolt 29 - Connecting Rod Bearing Cap 30 Lower Connecting Rod Bearing 31 - Upper Connecting Rod Bearing 32 - Connecting Rod 33 Piston Pin 34 - Piston 35 - Piston Oil Ring (With oil Ring Spacer) 36 - Lower Compression Ring 37 - Upper Compression Ring Engine Block Assembly - 1.4L LUH and LUJ Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2143 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Cylinder Head 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Baffle 16 - Oil Pan Baffle Bolt 17 - Oil Pan 18 - Oil Pan Bolt 19 - Oil Pan Drain Plug 20 - Crankshaft Position Sensor Bolt 21 - Crankshaft Position Sensor 22 - Crankshaft Position Sensor Seal Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2144 23 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 24 - Piston Oil Nozzle 25 - Crankshaft Position Sensor Reluctor Ring 26 - Crankshaft Position Sensor Reluctor Ring Bolt 27 - Crankshaft Rear Oil Seal 28 - Engine Flywheel (Two-Mass) 29 - Engine Flywheel Bolt 30 - Connecting Rod Bearing Cap Bolt 31 - Connecting Rod Bearing Cap 32 - Lower Connecting Rod Bearing 33 - Upper Connecting Rod Bearing 34 - Connecting Rod 35 - Piston Pin 36 - Piston Pin Retainer 37 - Piston Pin Retainer 38 - Piston 39 - Piston Oil Ring (With Oil Ring Spacer) 40 - Lower Compression Ring 41 - Upper Compression Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2145 Crankshaft Position Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Rear (LUJ) 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2146 Crankshaft Position Sensor: Diagrams Component Connector End Views B26 Crankshaft Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2147 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The crankshaft position sensor system variation learn procedure is required when the following service procedures have been performed, regardless of whether DTC P0315 00 is set: * Engine replacement * Engine control module (ECM) replacement * Crankshaft damper replacement * Crankshaft replacement * Crankshaft Position Sensor Replacement * Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Note: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the crankshaft position sensor system variation learn procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * Crankshaft Position Sensor activity - If there is a crankshaft position sensor condition, refer to the applicable DTC that set. * Camshaft position signal activity - If there is a camshaft position sensor signal condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT) - If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P0315 00, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select the Crankshaft Position System Variation Learn procedure and perform the following: 1. Observe the fuel cut-off for the applicable engine. 2. Block the drive wheels. 3. Set the parking brake. 4. Place the vehicles transmission in Park or Neutral. 5. Turn the air conditioning (A/C) OFF. 6. Cycle the ignition from OFF to ON. 7. Apply and hold the brake pedal for the duration of the procedure. 8. Start and idle the engine. 9. Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 10. Release the throttle when fuel cut-off occurs. ‹› Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC P0315 00 ran and passed, the crankshaft position sensor variation learn procedure is complete. If the scan tool indicates DTC P0315 00 failed or did not run, refer to DTC P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 5. Turn OFF the ignition for 30 s after the learn procedure is completed successfully. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2148 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Wheels/Vehicle Underbody Component Views Fuel Tank Components 1 - B150 Fuel Tank Pressure Sensor 2 - A7 Fuel Pump and Level Sensor Assembly 3 - Q13 Evaporative Emission (EVAP) Vent Solenoid Valve Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2152 Fuel Level Sensor: Diagrams Component Connector End Views A7 Fuel Pump and Level Sensor Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2153 Fuel Level Sensor: Service and Repair Fuel Sender Assembly Replacement Removal Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning: Refer to Safety Goggles and Fuel Warning (See: Fuel Delivery and Air Induction/Service Precautions/Safety Goggles and Fuel Warning). Caution: Use care while handling the fuel sender to prevent damage and incorrect fuel level readings. 1. Remove the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Tank Fuel Pump Module Replacement). 2. Disconnect the fuel sender assembly wiring harness plugs (1). 3. Unclip the 2 fuel sender retainer pins. 4. Remove the fuel sender assembly (2). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2154 1. Install the fuel sender assembly (2). 2. Connect the fuel sender assembly wiring harness plugs (1). 3. Install the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Tank Fuel Pump Module Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations Wheels/Vehicle Underbody Component Views Fuel Tank Components 1 - B150 Fuel Tank Pressure Sensor 2 - A7 Fuel Pump and Level Sensor Assembly 3 - Q13 Evaporative Emission (EVAP) Vent Solenoid Valve Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2158 Fuel Tank Pressure Sensor: Diagrams Component Connector End Views B150 Fuel Tank Pressure Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Front of Vehicle/Engine Compartment Component Views Right Front of the Vehicle Components 1 of 2 1 - B75B Mass Air Flow/Intake Air Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views Knock Sensor: Locations Disassembled Views Disassembled Views Engine Block Assembly - 1.4L LDD 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Engine Block 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views > Page 2166 16 - Oil Pan Bolt 17 - Oil Pan Drain Plug Seal Ring 18 - Oil Pan Drain Plug 19 - Crankshaft Position Sensor Bolt 20 - Crankshaft Position Sensor 21 - Crankshaft Position Sensor Seal Ring 22 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 23 - Crankshaft Position Sensor Reluctor Ring 24 Flywheel Bolt 25 - Engine Flywheel 26 - Crankshaft Rear Oil Seal 27 - Crankshaft Position Sensor Reluctor Ring Bolt 28 - Connecting Rod Bearing Cap Bolt 29 - Connecting Rod Bearing Cap 30 Lower Connecting Rod Bearing 31 - Upper Connecting Rod Bearing 32 - Connecting Rod 33 Piston Pin 34 - Piston 35 - Piston Oil Ring (With oil Ring Spacer) 36 - Lower Compression Ring 37 - Upper Compression Ring Engine Block Assembly - 1.4L LUH and LUJ Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views > Page 2167 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Cylinder Head 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Baffle 16 - Oil Pan Baffle Bolt 17 - Oil Pan 18 - Oil Pan Bolt 19 - Oil Pan Drain Plug 20 - Crankshaft Position Sensor Bolt 21 - Crankshaft Position Sensor 22 - Crankshaft Position Sensor Seal Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views > Page 2168 23 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 24 - Piston Oil Nozzle 25 - Crankshaft Position Sensor Reluctor Ring 26 - Crankshaft Position Sensor Reluctor Ring Bolt 27 - Crankshaft Rear Oil Seal 28 - Engine Flywheel (Two-Mass) 29 - Engine Flywheel Bolt 30 - Connecting Rod Bearing Cap Bolt 31 - Connecting Rod Bearing Cap 32 - Lower Connecting Rod Bearing 33 - Upper Connecting Rod Bearing 34 - Connecting Rod 35 - Piston Pin 36 - Piston Pin Retainer 37 - Piston Pin Retainer 38 - Piston 39 - Piston Oil Ring (With Oil Ring Spacer) 40 - Lower Compression Ring 41 - Upper Compression Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views > Page 2169 Knock Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Left Rear (LUJ) 1 - B111 Turbocharger Boost Pressure Sensor 2 - T8 Ignition Coil 3 - B68 Knock Sensor (KS) 4 Q38 Throttle Body 5 - B34 Engine Coolant Temperature Sensor Lower Rear of the Engine Components 1 of 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views > Page 2170 1 - B68 Knock Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2171 Knock Sensor: Description and Operation Knock Sensor System Description Circuit/System Description The knock sensor system enables the engine control module (ECM) to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The ECM uses the knock sensor system to test for abnormal engine noise that may indicate detonation, also known as spark knock. Sensor Description This knock sensor system uses one or two flat response dual-wire sensors. The sensor uses piezo-electric crystal technology that produces an alternating current (AC) voltage signal of varying amplitude and frequency based on the engine vibration or noise level. The amplitude and frequency are dependant upon the level of knock that the knock sensor detects. The ECM receives the knock sensor signal through 2 isolated signal circuits. If the ECM has determined that knock is present, it will retard the ignition timing to attempt to reduce the knock. The ECM is capable of controlling spark retard on an individual cylinder basis. The ECM will always try to work back to a zero compensation level, or no spark retard. knock sensor diagnostics are calibrated to detect faults with the knock sensor circuitry inside the ECM, the knock sensor wiring, or the knock sensor voltage output. Some diagnostics are also calibrated to detect constant noise from an outside influence such as a loose/damaged component or excessive mechanical engine noise. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2172 Knock Sensor: Service and Repair Knock Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Disassembled Views Manifold Pressure/Vacuum Sensor: Locations Disassembled Views Disassembled Views Intake Manifold Assembly - 1.4L LUH and LUJ 1 - Fuel Injector Fuel Rail 2 - Fuel Injector Fuel Rail Bolt 3 - Manifold Absolute Pressure Sensor 4 Manifold Absolute Pressure Sensor Bolt 5 - Evaporative Emission Canister Purge Solenoid Valve 6 - Intake Manifold 7 - Throttle Body Seal Ring 8 - Throttle Body 9 - Throttle Body Bolt 10 - Intake Manifold Gasket Intake Manifold Assembly - 1.4L LDD Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Disassembled Views > Page 2177 1 - Intake Manifold Sealings 2 - Intake Manifold (With Intake Manifold Runner and Intake Manifold Runner Valve) 3 - Throttle Body Bolt 4 - Throttle Body 5 - Throttle Body Seal Ring 6 - Fuel Injection Fuel Rail Bolt 7 - Evaporative Emission Canister Purge Solenoid Valve 8 - Evaporative Emission Canister Purge Solenoid Valve Rubber 9 - Evaporative Emission Canister Purge Solenoid Valve Bracket Bolt 10 - Evaporative Emission Canister Purge Solenoid Valve Bracket 11 - Fuel Injection Fuel Rail 12 - Fuel Injector Retainer Clamp 13 - Fuel Injector 14 - Manifold Absolute Pressure Sensor Bolt 15 - Manifold Absolute Pressure Sensor 16 - Manifold Absolute Pressure Sensor Seal Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Disassembled Views > Page 2178 Manifold Pressure/Vacuum Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Rear (LUJ) 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2179 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Disassembled Views Oxygen Sensor: Locations Disassembled Views Disassembled Views Exhaust Side - 1.4L LUH and LUJ 1 - Positive Crankcase Ventilation Pipe Assembly 2 - Exhaust Manifold Gasket 3 - Turbo Charger Oil Feed Pipe Hollow Screw 4 - Turbo Charger Oil Feed Pipe 5 - Turbo Charger Oil Feed Pipe Bolt 6 - Oil Cooler Coolant Outlet Hose 7 - Oil Cooler Coolant Outlet Hose Clamp 8 - Oil Cooler Coolant Feed Pipe Bolt 9 - Oil Cooler Coolant Feed Pipe 10 - Engine Oil Cooler Assembly 11 - Catalytic Converter Bracket 12 - Catalytic Converter to Catalytic Converter Bracket Nut 13 - Turbocharger Coolant Return Pipe 14 - Turbocharger Coolant Feed Pipe Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Disassembled Views > Page 2184 15 - Turbocharger Coolant Feed Pipe Hollow Screw 16 - Heated Oxygen Sensor 1 17 - Catalytic Converter 18 - Catalytic Converter Heat Shield 19 - Catalytic Converter Heat Shield Bolt 20 - Catalytic Converter Seal 21 - Catalytic Converter V-Clamp 22 - Turbocharger Oil Return Pipe 23 Turbocharger Oil Return Pipe Bolt 24 - Exhaust Manifold Heat Shield 25 - Exhaust Manifold Heat Shield Bolt 26 - Turbocharger (with Exhaust Manifold) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Disassembled Views > Page 2185 Oxygen Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Front (LUJ) 1 - Q6E Camshaft Position Actuator Solenoid Valve - Exhaust 2 - B23E Camshaft Position Sensor Exhaust 3 - B37 Engine Oil Pressure Switch 4 - B52A Heated Oxygen Sensor 1 5 - Q42 Turbocharger Wastegate Solenoid Valve 6 - Q2 A/C Compressor Clutch Engine Components - Right Rear (LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Disassembled Views > Page 2186 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Caution > Page 2189 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Caution > Page 2190 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Sensor 1 Heated Oxygen Sensor Replacement - Sensor 1 (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Sensor 1 > Page 2193 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Sensor 2 Heated Oxygen Sensor Replacement - Sensor 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair Transmission Position Switch/Sensor: Service and Repair Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Special Tools DT-41229 - Manual Shaft Pin Installer For equivalent regional tools, refer to Special Tools (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Tools and Equipment). Removal Procedure 1. Remove the control valve body. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 2. Remove the manual shaft detent lever hub pin (1) using a pry bar and pliers. 3. Remove and DISCARD the manual shift shaft pin (5). 4. Remove the manual shaft (2). 5. Disconnect the actuator rod (3) from the detent lever assembly. Do not remove the actuator rod from the transmission case. 6. Remove the manual shaft detent (with shift position switch) lever assembly (4). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Page 2197 1. Connect the actuator rod (3) to the detent lever assembly. 2. Install the manual shaft detent (with shift position switch) lever assembly (4). 3. Install the manual shaft (2). 4. Install the manual shaft detent lever hub pin (1) to height of 7.9 mm (0.38 in) (b). Caution: Use J 41229 to install the manual shaft pin at the correct height in order to properly secure the manual shaft. If you install the pin too deep, the case bore may crack. 5. Install the NEW manual shift shaft pin (5) using DT-41229 - pin installer. Use a NEW pin to ensure proper engagement with the case. 6. Inspect pin installed height is within 7.2-8.2 mm (0.28-0.32 in) (a). 7. Install the control valve body. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 8. Perform the transmission adaptive values learn procedure. Refer to Transmission Adaptive Values Learn (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2202 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views B107 Accelerator Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2203 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Right Front of the Vehicle Components 1 of 2 1 - B75B Mass Air Flow/Intake Air Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2207 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor Replacement (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair Fuel Pressure Sensor/Switch: Service and Repair Fuel Pressure Sensor Replacement Removal Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning: Refer to Safety Goggles and Fuel Warning (See: Fuel Delivery and Air Induction/Service Precautions/Safety Goggles and Fuel Warning). 1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the fuel pressure sensor wiring harness plug (2) from the fuel pressure sensor (1). 4. Remove the fuel pressure sensor (1) from the fuel pressure relief valve (2). 5. Remove the fuel pressure sensor seal ring (3). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Page 2211 Installation Procedure 1. Install a NEW fuel pressure sensor seal ring (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the fuel pressure sensor (1) to the fuel pressure relief valve (2) and tighten to 19 Nm (14 lb ft). 3. Plug the fuel pressure sensor wiring harness plug (2) to the fuel pressure sensor (1). 4. Lower the vehicle. 5. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations Oil Pressure Switch (For Fuel Pump): Locations Disassembled Views Cylinder Head Assembly 1 - Camshaft Cover 2 - Oil Level Indicator 3 - Camshaft Cover Bolt 4 - Oil Filler Cap 5 - Oil Filler Cap Seal Ring 6 - Camshaft Cover Gasket 7 - Camshaft Bearing Cap Bolt 8 - Camshaft Bearing Cap 9 - Cylinder Head Bolt 10 - Valve Keys 11 - Valve Spring Retainer 12 - Valve Spring 13 Engine Lift Bracket Left Side 14 - Engine Lift Bracket Bolt 15 - Cylinder Head 16 - Intake Valve Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 2215 17 - Exhaust Valve 18 - Engine Lift Bracket 19 - Engine Lift Bracket Bolt 20 - Engine Lift Bracket 21 - Engine Lift Bracket Bolt 22 - Oil Pressure Indicator Switch 23 - Oil Pressure Indicator Switch Seal Ring 24 - Hydraulic Valve Lash Adjuster 25 - Hydraulic Valve Lash Adjuster Arm 26 - Exhaust Camshaft 27 - Intake Camshaft Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 2216 Oil Pressure Switch (For Fuel Pump): Service and Repair Engine Oil Pressure Indicator Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations Turbo Boost Sensor: Locations Powertrain Component Views Engine Components - Left Rear (LUJ) 1 - B111 Turbocharger Boost Pressure Sensor 2 - T8 Ignition Coil 3 - B68 Knock Sensor (KS) 4 Q38 Throttle Body 5 - B34 Engine Coolant Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle Camshaft Position Sensor: Customer Interest Engine - Lack of Power with Multiple DTCs or Rattle TECHNICAL Bulletin No.: 10-06-04-016 Date: December 20, 2010 Subject: Engine Lack of Power with DTCs P0011, P0014, P000A, P000B, P0012, P0015 or Engine Rattle Noise (Remove Oil Filters from Intake and Exhaust Camshaft Position Actuator Solenoid Valves) Models: 2008-2011 Chevrolet Aveo 2011 Chevrolet Cruze (US and Canada) 2009-2011 Chevrolet Cruze (Export Only) 2008-2009 Pontiac G3, Wave 2008-2009 Saturn Astra Condition Some customers may comment on lack of power with the following DTCs or an engine rattle noise from the sprockets. Cruze GEN3 1.6/1.8D - P0011: Intake Camshaft Position (CMP) System Performance - P0014: Exhaust Camshaft Position (CMP) System Performance - P000A: Intake Camshaft Position System Slow Response - P000B: Exhaust Camshaft Position System Slow Response Aveo GEN3 1.4D - P0012: Intake Camshaft Position (CMP) System Performance Bank 1-Retarded - P0015: Exhaust Camshaft Position (CMP) System Performance Bank 1-Retarded Aveo/G3/Wave Gen3 1.6D - P0011: Intake Camshaft Position (CMP) System Performance Bank 1 - P0014: Exhaust Camshaft Position (CMP) System Performance Bank 1 Correction Remove four oil filters from the intake and exhaust camshaft position actuator solenoid valves. 1. Open the hood. 2. Disconnect the negative battery cable. 3. Disconnect the camshaft position actuator solenoid valve connectors. 4. Remove the power steering line bracket bolt and reposition the bracket (for 1.6/1.8L only). 5. Disconnect PCV pipe and reposition (for 1.6/1.8L only). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 2229 6. Remove the camshaft position actuator solenoid valve bolts. 7. Remove the camshaft position actuator solenoid valves and seals. 8. Check whether the filter is broken or not (1). 9. Remove the four filters (intake and exhaust). 1. Broken Filter: Remove filter with a blunt tool. 2. Unbroken Filter 1. Locate the filter hinge between the holes. 2. Cut the filter hinge slightly. Caution Do not scratch the valve surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 2230 3. Remove the filter with a blunt tool. 10. Install the camshaft position actuator solenoid valves and seals. Coat the seal with clean engine oil prior to installation. 11. Install the camshaft position actuator solenoid valve bolts. Tighten Tighten the bolts to 6 Nm (53 lb in). 12. Connect the camshaft position actuator solenoid valve connectors. 13. Reposition and install the PCV pipe (for 1.6/1.8 only). 14. Reposition the power steering bracket and install the power steering line bracket bolt (for 1.6/1.8 only). 15. Connect the negative battery cable. Note If an engine rattle noise is heard after removing the filters, refer to SI for further diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle Camshaft Position Sensor: All Technical Service Bulletins Engine - Lack of Power with Multiple DTCs or Rattle TECHNICAL Bulletin No.: 10-06-04-016 Date: December 20, 2010 Subject: Engine Lack of Power with DTCs P0011, P0014, P000A, P000B, P0012, P0015 or Engine Rattle Noise (Remove Oil Filters from Intake and Exhaust Camshaft Position Actuator Solenoid Valves) Models: 2008-2011 Chevrolet Aveo 2011 Chevrolet Cruze (US and Canada) 2009-2011 Chevrolet Cruze (Export Only) 2008-2009 Pontiac G3, Wave 2008-2009 Saturn Astra Condition Some customers may comment on lack of power with the following DTCs or an engine rattle noise from the sprockets. Cruze GEN3 1.6/1.8D - P0011: Intake Camshaft Position (CMP) System Performance - P0014: Exhaust Camshaft Position (CMP) System Performance - P000A: Intake Camshaft Position System Slow Response - P000B: Exhaust Camshaft Position System Slow Response Aveo GEN3 1.4D - P0012: Intake Camshaft Position (CMP) System Performance Bank 1-Retarded - P0015: Exhaust Camshaft Position (CMP) System Performance Bank 1-Retarded Aveo/G3/Wave Gen3 1.6D - P0011: Intake Camshaft Position (CMP) System Performance Bank 1 - P0014: Exhaust Camshaft Position (CMP) System Performance Bank 1 Correction Remove four oil filters from the intake and exhaust camshaft position actuator solenoid valves. 1. Open the hood. 2. Disconnect the negative battery cable. 3. Disconnect the camshaft position actuator solenoid valve connectors. 4. Remove the power steering line bracket bolt and reposition the bracket (for 1.6/1.8L only). 5. Disconnect PCV pipe and reposition (for 1.6/1.8L only). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 2236 6. Remove the camshaft position actuator solenoid valve bolts. 7. Remove the camshaft position actuator solenoid valves and seals. 8. Check whether the filter is broken or not (1). 9. Remove the four filters (intake and exhaust). 1. Broken Filter: Remove filter with a blunt tool. 2. Unbroken Filter 1. Locate the filter hinge between the holes. 2. Cut the filter hinge slightly. Caution Do not scratch the valve surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 2237 3. Remove the filter with a blunt tool. 10. Install the camshaft position actuator solenoid valves and seals. Coat the seal with clean engine oil prior to installation. 11. Install the camshaft position actuator solenoid valve bolts. Tighten Tighten the bolts to 6 Nm (53 lb in). 12. Connect the camshaft position actuator solenoid valve connectors. 13. Reposition and install the PCV pipe (for 1.6/1.8 only). 14. Reposition the power steering bracket and install the power steering line bracket bolt (for 1.6/1.8 only). 15. Connect the negative battery cable. Note If an engine rattle noise is heard after removing the filters, refer to SI for further diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Disassembled Views Camshaft Position Sensor: Locations Disassembled Views Disassembled Views Engine Front Cover And Oil Pump Assembly (1 of 2) 1 - Camshaft Position Actuator Solenoid Valve Bolt 2 - Intake Camshaft Position Actuator Solenoid Valve 3 - Exhaust Camshaft Position Actuator Solenoid Valve 4 - Intake Camshaft Position Sensor Bolt 5 - Intake Camshaft Position Sensor 6 - Intake Camshaft Position Sensor Seal Ring 7 - Engine Front Cover 8 - Engine Front Cover Gasket 9 - Exhaust Camshaft Position Sensor Seal Ring 10 Exhaust Camshaft Position Sensor 11 - Exhaust Camshaft Position Sensor Bolt 12 - Engine Front Cover Oil Gallery Plug 13 - Engine Front Cover Oil Gallery Plug Seal Ring 14 - Oil Pressure Relief Valve Piston 15 - Oil Pressure Relief Valve Spring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2240 16 - Oil Pressure Relief Valve Plug 17 - Engine Front Cover Bolt (M10) 18 - Crankshaft Front Oil Seal 19 - Engine Front Cover Bolt (M6) 20 - Water Drain Plug Seal Ring 21 - Water Drain Plug 22 - Exhaust Camshaft Position Actuator Solenoid Valve Bolt Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2241 Camshaft Position Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Front (LUJ) 1 - Q6E Camshaft Position Actuator Solenoid Valve - Exhaust 2 - B23E Camshaft Position Sensor Exhaust 3 - B37 Engine Oil Pressure Switch 4 - B52A Heated Oxygen Sensor 1 5 - Q42 Turbocharger Wastegate Solenoid Valve 6 - Q2 A/C Compressor Clutch Engine Components - Right Rear (LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2242 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2243 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Open hood. Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 2. Disconnect the camshaft position sensor wiring harness plug (1). Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 3. Remove the camshaft position sensor bolt (3). 4. Remove the camshaft position sensor (2) and the seal ring (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2244 Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 1. Install the camshaft position sensor (2) and the seal ring (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 2. Install the camshaft position sensor bolt (3) and tighten to 8 Nm (71 lb in). Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 3. Connect the camshaft position sensor wiring harness plug (1). 4. After replacement of an camshaft position sensor, use a scan tool to speed up learn function. Refer to Engine Control Module Programming and Setup (LUW, LUJ) (See: Testing and Inspection/Programming and Relearning/Engine Control Module Programming and Setup) 5. Close hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views Crankshaft Position Sensor: Locations Disassembled Views Disassembled Views Engine Block Assembly - 1.4L LDD 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Engine Block 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2249 16 - Oil Pan Bolt 17 - Oil Pan Drain Plug Seal Ring 18 - Oil Pan Drain Plug 19 - Crankshaft Position Sensor Bolt 20 - Crankshaft Position Sensor 21 - Crankshaft Position Sensor Seal Ring 22 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 23 - Crankshaft Position Sensor Reluctor Ring 24 Flywheel Bolt 25 - Engine Flywheel 26 - Crankshaft Rear Oil Seal 27 - Crankshaft Position Sensor Reluctor Ring Bolt 28 - Connecting Rod Bearing Cap Bolt 29 - Connecting Rod Bearing Cap 30 Lower Connecting Rod Bearing 31 - Upper Connecting Rod Bearing 32 - Connecting Rod 33 Piston Pin 34 - Piston 35 - Piston Oil Ring (With oil Ring Spacer) 36 - Lower Compression Ring 37 - Upper Compression Ring Engine Block Assembly - 1.4L LUH and LUJ Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2250 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Cylinder Head 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Baffle 16 - Oil Pan Baffle Bolt 17 - Oil Pan 18 - Oil Pan Bolt 19 - Oil Pan Drain Plug 20 - Crankshaft Position Sensor Bolt 21 - Crankshaft Position Sensor 22 - Crankshaft Position Sensor Seal Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2251 23 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 24 - Piston Oil Nozzle 25 - Crankshaft Position Sensor Reluctor Ring 26 - Crankshaft Position Sensor Reluctor Ring Bolt 27 - Crankshaft Rear Oil Seal 28 - Engine Flywheel (Two-Mass) 29 - Engine Flywheel Bolt 30 - Connecting Rod Bearing Cap Bolt 31 - Connecting Rod Bearing Cap 32 - Lower Connecting Rod Bearing 33 - Upper Connecting Rod Bearing 34 - Connecting Rod 35 - Piston Pin 36 - Piston Pin Retainer 37 - Piston Pin Retainer 38 - Piston 39 - Piston Oil Ring (With Oil Ring Spacer) 40 - Lower Compression Ring 41 - Upper Compression Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2252 Crankshaft Position Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Rear (LUJ) 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2253 Crankshaft Position Sensor: Diagrams Component Connector End Views B26 Crankshaft Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2254 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The crankshaft position sensor system variation learn procedure is required when the following service procedures have been performed, regardless of whether DTC P0315 00 is set: * Engine replacement * Engine control module (ECM) replacement * Crankshaft damper replacement * Crankshaft replacement * Crankshaft Position Sensor Replacement * Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Note: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the crankshaft position sensor system variation learn procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * Crankshaft Position Sensor activity - If there is a crankshaft position sensor condition, refer to the applicable DTC that set. * Camshaft position signal activity - If there is a camshaft position sensor signal condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT) - If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P0315 00, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select the Crankshaft Position System Variation Learn procedure and perform the following: 1. Observe the fuel cut-off for the applicable engine. 2. Block the drive wheels. 3. Set the parking brake. 4. Place the vehicles transmission in Park or Neutral. 5. Turn the air conditioning (A/C) OFF. 6. Cycle the ignition from OFF to ON. 7. Apply and hold the brake pedal for the duration of the procedure. 8. Start and idle the engine. 9. Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 10. Release the throttle when fuel cut-off occurs. ‹› Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC P0315 00 ran and passed, the crankshaft position sensor variation learn procedure is complete. If the scan tool indicates DTC P0315 00 failed or did not run, refer to DTC P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 5. Turn OFF the ignition for 30 s after the learn procedure is completed successfully. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2255 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair Key and Lock Cylinder Coding Ignition Lock Cylinder The ignition lock cylinder uses 8 key cut positions, 1-8. The tumbler positions are staggered from side to side, four on one side and four on the other. Note: The tumblers (5) are not self-retaining and must be held in place if the key is not fully inserted into the lock cylinder or until the cylinder (2) is assembled into the case assembly (8). 1. Hold the cylinder assembly (2) so that the retainer pin pocket is facing upward. 2. Insert one tumbler spring (4) into each of the 4 spring wells. 3. The first tumbler (5) to be loaded will be the first key cut position, the first number in the key code. Install the first tumbler in the slot nearest the head of the lock cylinder. Install the remaining tumblers following the key code into the slots at the key cut positions 3, 5 and 7. It may be necessary to move the sidebar (already pre-assembled into the cylinder assembly) out slightly to fully install the tumbler into the correct slot. 4. Check the correct loading by holding the tumblers (5) in position and fully inserting the key into the cylinder assembly (2). All tumblers and the sidebar should be flushed with the outside diameter of the cylinder assembly body. 5. Rotate the cylinder assembly (2) so that the retention lug is facing upward and then remove the key, always holding all tumblers so they do not fall out. 6. Insert one tumbler spring (4) into each of the 4 spring wells. 7. The first tumbler (5) to be loaded will be the second key cut position, the second number in the key code. Install the tumbler in the slot nearest the head of the lock cylinder. Install the remaining tumblers following the key code into the slots at the key cut positions 4, 6 and 8. 8. Check for the correct loading by holding the tumblers (5) in position and fully inserting the key into the cylinder assembly (2). 9. Lightly lubricate the tumbler (5) surfaces and the small detent recess on the side of the cylinder assembly (2) using the lubrication provided. 10. With the key fully inserted, rotate the cylinder assembly so that the side with the retaining pin (7) pocket is facing upward. 11. Insert the retaining pin spring (6) and then retaining pin (7) into the pocket located behind the 4 tumblers. The retaining pin spring and retaining pin are not self-retaining and must be held in place until the cylinder is installed into the case assembly (8). 12. With the key fully inserted into the cylinder assembly and the retaining pin (7) fully depressed into the cylinder, align the retainer lug on the cylinder with the groove on the inside diameter of the case assembly (8). This groove extends the full length of the case assembly. 13. Install the cylinder assembly into the case assembly (8) being very careful to hold the retainer pin spring (6) and retainer pin (7) in the cylinder until they enter into the case assembly. With the cylinder fully inserted into the case assembly, rotate the cylinder counterclockwise until the retainer pin (7) snaps into place limiting the rotation of the cylinder assembly. 14. With the cylinder assembly in the Off-Lock position, insert the detent rod (1) into the hole in the side of the case assembly (8). Install the anti-rattle spring (3) into the case assembly over the detent spring. The anti-rattle spring should capture the detent ball and spring in the case assembly. Make sure both ends of the anti-rattle spring (3) are fully seated, pressed into, the case assembly. 15. With the cylinder assembly in the Off-Lock position, insert the detent rod (1) into the hole in the side of the case assembly (8). Install the anti-rattle spring (3) into the case assembly over the detent spring. The anti-rattle spring should capture the detent ball and spring in the case assembly. Make sure both ends of the anti-rattle spring (3) are fully seated, pressed into, the case assembly. Front Side Door Lock Cylinder Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Page 2260 1. Rotate the cylinder (8) so that the side with the tumbler spring wells faces up. 2. Insert the tumbler springs (4) into the 4 spring wells. 3. Install the tumbler (10) for key cut position 3 in the slot closest to the cylinder head. Install the remaining tumblers, key cut positions 5, 7 and 9, following the key code and same process. Press the tumblers in place until they are secure. 4. Check the correct loading of the tumblers by inserting the key into the cylinder. All tumblers should be flushed with the lock cylinder body. 5. Turn the cylinder so the side with the other tumbler spring wells faces up. 6. Insert the tumbler springs (4) into the 4 spring wells. 7. The first tumbler closest to the head of the lock cylinder to be loaded will be the fourth key cut position. Install the remaining tumblers for key cut positions 6, 8 and 10. Press the tumblers in place until they are secure. 8. Check the correct loading of the tumblers by inserting the key into the cylinder. All of the tumblers should be flushed with the lock cylinder body. 9. Apply lubricant to the cylinder body and tumbler surfaces along with a small amount in the head of the cylinder using the supplied lubricant. 10. Install the retainer (5) into the spring wells in the head of the lock cylinder. 11. Snap the shutter (7) into the cylinder. 12. Assemble the cylinder into the case (3). 13. Align dimples of the cylinder cap (6) with the 4 recesses in the cap. Secure by pressing the cap into place with light hand pressure. 14. Assemble the rod clip (2) to the lever (1). 15. Assemble the lever (1) to the lock. Use driver unit (11) to retain the lever assembly. 16. Assemble the gasket to the lock. 17. Insert the key into the lock and function the lock to check for proper assembly and smooth operation. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views Knock Sensor: Locations Disassembled Views Disassembled Views Engine Block Assembly - 1.4L LDD 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Engine Block 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views > Page 2265 16 - Oil Pan Bolt 17 - Oil Pan Drain Plug Seal Ring 18 - Oil Pan Drain Plug 19 - Crankshaft Position Sensor Bolt 20 - Crankshaft Position Sensor 21 - Crankshaft Position Sensor Seal Ring 22 Crankshaft Bearing Cap Tie Plate Bolt (M8) 23 - Crankshaft Position Sensor Reluctor Ring 24 Flywheel Bolt 25 - Engine Flywheel 26 - Crankshaft Rear Oil Seal 27 - Crankshaft Position Sensor Reluctor Ring Bolt 28 - Connecting Rod Bearing Cap Bolt 29 - Connecting Rod Bearing Cap 30 Lower Connecting Rod Bearing 31 - Upper Connecting Rod Bearing 32 - Connecting Rod 33 Piston Pin 34 - Piston 35 - Piston Oil Ring (With oil Ring Spacer) 36 - Lower Compression Ring 37 - Upper Compression Ring Engine Block Assembly - 1.4L LUH and LUJ Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views > Page 2266 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Cylinder Head 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Baffle 16 - Oil Pan Baffle Bolt 17 - Oil Pan 18 - Oil Pan Bolt 19 - Oil Pan Drain Plug 20 - Crankshaft Position Sensor Bolt 21 - Crankshaft Position Sensor 22 - Crankshaft Position Sensor Seal Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views > Page 2267 23 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 24 - Piston Oil Nozzle 25 - Crankshaft Position Sensor Reluctor Ring 26 - Crankshaft Position Sensor Reluctor Ring Bolt 27 - Crankshaft Rear Oil Seal 28 - Engine Flywheel (Two-Mass) 29 - Engine Flywheel Bolt 30 - Connecting Rod Bearing Cap Bolt 31 - Connecting Rod Bearing Cap 32 - Lower Connecting Rod Bearing 33 - Upper Connecting Rod Bearing 34 - Connecting Rod 35 - Piston Pin 36 - Piston Pin Retainer 37 - Piston Pin Retainer 38 - Piston 39 - Piston Oil Ring (With Oil Ring Spacer) 40 - Lower Compression Ring 41 - Upper Compression Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views > Page 2268 Knock Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Left Rear (LUJ) 1 - B111 Turbocharger Boost Pressure Sensor 2 - T8 Ignition Coil 3 - B68 Knock Sensor (KS) 4 Q38 Throttle Body 5 - B34 Engine Coolant Temperature Sensor Lower Rear of the Engine Components 1 of 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views > Page 2269 1 - B68 Knock Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2270 Knock Sensor: Description and Operation Knock Sensor System Description Circuit/System Description The knock sensor system enables the engine control module (ECM) to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The ECM uses the knock sensor system to test for abnormal engine noise that may indicate detonation, also known as spark knock. Sensor Description This knock sensor system uses one or two flat response dual-wire sensors. The sensor uses piezo-electric crystal technology that produces an alternating current (AC) voltage signal of varying amplitude and frequency based on the engine vibration or noise level. The amplitude and frequency are dependant upon the level of knock that the knock sensor detects. The ECM receives the knock sensor signal through 2 isolated signal circuits. If the ECM has determined that knock is present, it will retard the ignition timing to attempt to reduce the knock. The ECM is capable of controlling spark retard on an individual cylinder basis. The ECM will always try to work back to a zero compensation level, or no spark retard. knock sensor diagnostics are calibrated to detect faults with the knock sensor circuitry inside the ECM, the knock sensor wiring, or the knock sensor voltage output. Some diagnostics are also calibrated to detect constant noise from an outside influence such as a loose/damaged component or excessive mechanical engine noise. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2271 Knock Sensor: Service and Repair Knock Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURE Fuel Pressure (Key ON, Engine OFF).................................................................................................. .............................................250-450 kPa (36-65 PSI) Should not decrease greater than........................................................................................................ .................................................34 kPa (5 PSI) in 1 min Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2276 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description When the ignition is turned ON, the engine control module (ECM) supplies power to the in-tank fuel pump, by energizing the fuel pump relay. The in-tank fuel pump remains ON as long as the engine is cranking or running and the ECM receives crankshaft reference pulses. If there are no reference pulses, the ECM turns the in-tank fuel pump OFF, 2 s after the ignition switch is turned ON or 2 s after the engine stops running. The electric fuel pump is incorporated into the modular fuel pump and sender assembly and is located inside the fuel tank. The fuel pump supplies fuel through a fuel filter, also located in the modular fuel pump and sender assembly, through the fuel feed pipes, to the fuel rail assembly. The fuel pump provides fuel at a pressure above the pressure needed by the fuel injectors. The fuel pressure regulator, located in the modular fuel pump and sender assembly, keeps the fuel available to the fuel injectors at a regulated pressure. When the fuel pressure rises above the pressure regulator calibration, the pressure is relieved, with excess fuel exhausted into the modular fuel pump and sender assembly reservoir. Reference Information Description and Operation Fuel System Description (See: Computers and Control Systems/Description and Operation/Fuel System Description) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Special Tools * CH 48027 - Digital Pressure Gauge * EN 37287 - Fuel Line Shut-Off Adapters For equivalent regional tools, refer to Special Tools (See: Computers and Control Systems/Tools and Equipment). Circuit/System Verification Note: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that an adequate amount of fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. 1. Ignition ON, command the KR23A Fuel Pump Relay ON with a scan tool. You should hear the G12 Fuel Pump turn ON and OFF. ‹› If the G12 Fuel Pump does not turn ON, refer to Fuel Pump Electrical Circuit Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Pump Electrical Circuit Diagnosis). 2. Ignition OFF, all accessories OFF, install the CH 48027 - Digital Pressure Gauge. 3. Ignition ON, command the KR23A Fuel Pump Relay ON with a scan tool. Verify the fuel pressure is between 250-450 kPa (36-65 PSI) and remains steady for 5 m. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 2279 Circuit/System Testing Note: * The KR23A Fuel Pump Relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Do not start the engine. 1. Ignition ON, engine OFF, command the KR23A Fuel Pump Relay ON with a scan tool and observe the fuel pressure gauge while the G12 Fuel Pump is operating. Verify the fuel pressure is between 250-450 kPa (36-65 PSI). ‹› If the fuel pressure is greater than the specified range, replace the G12 Fuel Pump. ‹› If the fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all items test normal, replace the G12 Fuel Pump. * Restricted fuel feed pipe * Restricted or clogged strainer * Restricted or plugged fuel filter * Inspect the G12 Fuel Pump harness connectors and the ground circuits of the fuel pump for poor connections. Note: The fuel pressure may vary slightly when the G12 Fuel Pump stops operating. After the G12 Fuel Pump stops operating, the fuel pressure should stabilize and remain constant. 2. Verify the fuel pressure does not decrease greater than 34 kPa (5 PSI) in 1 min. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve fuel pressure. 2. Install the EN 37287 - Fuel Line Shut-Off Adapters between the fuel feed pipe and the fuel rail. 3. Open the valve on the EN 37287 - Fuel Line Shut-Off Adapters. 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the digital pressure gauge. 5. Close the valve on the EN 37287 - Fuel Line Shut-Off Adapters. 6. Verify the fuel pressure does not decrease greater than 34 kPa (5 PSI) in 1 minute. ‹› If the fuel pressure decreases more than 34 kPa (5 PSI) within the specified time, locate and replace the leaking fuel injector(s). ‹› If the fuel pressure does not decrease more than 34 kPa (5 PSI) within the specified time, replace the G12 Fuel Pump. 3. Relieve the fuel pressure to 69 kPa (10 PSI). Verify that the fuel pressure does not decrease more than 14 kPa (2 PSI) in 5 min. ‹› If the fuel pressure decreases more than the specified value, replace the G12 Fuel Pump. 4. Remove the EN 37287 - Fuel Line Shut-Off Adapters and CH 48027 - Digital Pressure Gauge. 5. Operate the vehicle within the conditions of the customers concern while monitoring fuel related parameters with a scan tool. The scan tool parameters should not indicate a lean condition. ‹› If the scan tool parameters indicate a lean condition, test for a restricted fuel feed pipe, restricted fuel filter, or poor connections at the harness connectors and ground circuits of the fuel pump. If all test normal, replace the fuel pump. 6. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls). Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 2280 Fuel Pressure: Testing and Inspection Fuel Pressure Measurement Fuel Pressure Measurement Special Tools EN-34730-91 - Pressure Tester For equivalent regional tools, refer to Special Tools (See: Computers and Control Systems/Tools and Equipment) Warning Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Remove the protective cap from the test connection. 2. Attach the EN-34730-91 - tester (1) to the test connection. 3. Start the engine. * Bleed the pressure tester at idling speed. * Collect the exiting fuel in a suitable container. * Read the fuel pressure from the pressure gauge. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 4. Detach the pressure gauge EN-34730-91 - tester from the test connection. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > System Diagnosis Idle Speed: Testing and Inspection Throttle/Idle Learn The Idle Learn Procedure listed below must be performed whenever the following occurs: The crankshaft position variation learn procedure is also required when the following service procedures have been performed, regardless of whether or not DTC P0315 00 is set: * The throttle body assembly is replaced. * The throttle body is cleaned. * The engine control module (ECM) is replaced. * The idle air control valve is replaced. * Power disconnection (battery cable, ECM fuse, etc.) (Delphi ECM only) 1. Turn the ignition ON. 2. Turn the ignition OFF for 15 s. 3. Turn the ignition ON for 5 s. 4. Turn the ignition OFF for 15 s. 5. Start the engine in park/neutral. 6. Allow the engine to run until the engine coolant temperature is greater than 85°C (185°F). 7. Turn the A/C ON for 10 s, if equipped. 8. If the vehicle is equipped with an automatic transaxle, apply the parking brake. While pressing the brake pedal, place the transaxle in drive for 10 s. 9. Turn the A/C OFF for 10 s, if equipped. 10. If the vehicle is equipped with an automatic transaxle, while pressing the brake pedal, place the transaxle in park/neutral. 11. Turn the ignition OFF. The idle learn procedure is complete. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 2289 Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Inlet Duct Replacement Air Cleaner Inlet Duct Replacement Removal Procedure 1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 2. Remove the intake air duct bolt (2). 3. Remove the intake air duct (1) Installation Procedure 1. Install the intake air duct (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 2290 2. Install and tighten the intake air duct bolt (2). 3. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement (1.4L LUH and LUJ) Removal Procedure 1. Open hood. 2. Disconnect mass air flow sensor wiring harness plug (2) from mass air flow sensor (3). 3. Unclip mass air flow sensor wiring harness retainer clip from air cleaner housing (1). 4. Remove the air cleaner outlet duct clamp (3). 5. Remove the air cleaner outlet duct (2) from air cleaner housing (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2294 6. Remove the 5 air cleaner housing bolts (1). 7. Remove the air cleaner upper housing (2) from the air cleaner lower housing (4). 8. Remove the air cleaner element (3). Installation Procedure 1. Install the air cleaner element (3). 2. Install the air cleaner upper housing (2) to the air cleaner lower housing (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 5 air cleaner housing bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2295 4. Install the air cleaner outlet duct (2) to the air cleaner housing (1). 5. Install the air cleaner outlet duct clamp (3). 6. Clip in mass air flow sensor wiring harness retainer clip to air cleaner housing (1). 7. Connect the mass air flow sensor wiring harness plug 2) to the mass air flow sensor (3). 8. Close hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Special Tools EN-34730-91 - Pressure Tester For equivalent regional tools, refer to Special Tools (See: Computers and Control Systems/Tools and Equipment). Warning Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. Warning Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Remove the fuel injector rail cap (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 2300 2. Relieve the fuel pressure. Use EN-34730-91 - pressure tester (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Ignition System Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Ignition System Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2307 Spark Plug: Application and ID Ignition System Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2308 Spark Plug: Testing and Inspection Spark Plug Inspection Spark Plug Usage 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications ( See: Application and ID) for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: * Spark plug fouling-Colder plug * Pre-ignition causing spark plug and/or engine damage-Hotter plug Spark Plug Inspection 1. Inspect the terminal post (1) for damage. * Inspect for a bent or broken terminal post (1). * Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: * Inspect the spark plug boot for damage. * Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2309 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. * Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications (See: Application and ID). An excessively wide electrode gap can prevent correct spark plug operation. * Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Application and ID). Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. * Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). * Inspect for a broken or worn side electrode (3). * Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. 5. A rattling sound indicates internal damage. 6. A loose center electrode (4) reduces the spark intensity. * Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. * Inspect for worn or missing platinum pads on the electrodes (3, 4) If equipped. * Inspect for excessive fouling. * Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Spark Plug Visual Inspection 1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: * Rich fuel mixtures * Leaking fuel injectors * Excessive fuel pressure * Restricted air filter element * Incorrect combustion * Reduced ignition system voltage output * Weak coils * Worn ignition wires * Incorrect spark plug gap * Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. * Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2310 Spark Plug: Service and Repair Spark Plug Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications All 4 cylinders must be tested to obtain valid test results. Record the readings. Maximum pressure differential............................................................................................................. .......................................................100 kPa (14.5 psi) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2314 Compression Check: Testing and Inspection Engine Compression Test Special Tools EN-48248 - Cylinder Compression Pressure Gauge For equivalent regional tools, refer to Special Tools (See: Engine, Cooling and Exhaust/Engine/Tools and Equipment). Removal Procedure 1. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement (1.4L LUH and LUJ) (See: Fuel Delivery and Air Induction/Throttle Body/Service and Repair/Removal and Replacement). 2. Remove the spark plugs. Refer to Spark Plug Replacement (See: Spark Plug/Service and Repair). 3. Remove the relay holder cover. 4. Remove the fuel pump relay. Note: The engine cranking time for the compression test should be less then 10 seconds and at 30 second intervals. 5. Crank the engine with the starter motor for 5 seconds to remove any foreign substances from the cylinders. 6. Prior to taking a compression reading, verify the cranking speed is greater than 300 RPM. If the cranking speed is below 300 RPM, repair the slow cranking speed condition before continuing with the compression test. 7. Install EN-48248 - gauge in the spark plug bore for the cylinder that is being checked. 8. Using the vehicle's starter motor, rotate or crank the engine for 4 compression strokes, puffs, for the cylinder being tested. 9. Observe the compression gauge and note the reading as the compression test is being performed. A normal cylinder reading will be indicated if compression builds up quickly and evenly to the specified level. An abnormal reading will be indicated if compression is low on the first compression stroke, starts increasing on the following compression strokes but does not reach the specified level. 10. Record the compression reading for the cylinder just tested. 11. Repeat steps for all remaining cylinders. All 4 cylinders must be tested to obtain valid test results. Record the readings. 12. Maximum pressure differential 100 kPa (14.5 psi). Installation Procedure 1. Install the fuel pump relay. 2. Install the relay holder cover. 3. Install the spark plugs. Refer to Spark Plug Replacement (See: Spark Plug/Service and Repair). 4. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement (1.4L LUH and LUJ) (See: Fuel Delivery and Air Induction/Throttle Body/Service and Repair/Removal and Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2319 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views B107 Accelerator Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2320 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Right Front of the Vehicle Components 1 of 2 1 - B75B Mass Air Flow/Intake Air Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2324 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor Replacement (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Front of Vehicle/Engine Compartment Component Views Right Front of the Vehicle Components 1 of 2 1 - B75B Mass Air Flow/Intake Air Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations Barometric Pressure Sensor: Locations Powertrain Component Views Engine Components - Right Rear (LUJ) 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor > Component Information > Locations Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Side of the Engine Compartment Components 2 of 2 1 - B18 Battery Current Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor > Component Information > Locations > Page 2334 Battery Current Sensor: Diagrams Component Connector End Views B18 Battery Current Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor > Component Information > Locations > Page 2335 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Open the hood. 2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Remove the battery ground cable nut (1). 4. Remove the battery negative cable (2). 5. Disconnect the wiring harness current sensor plug (4). 6. Remove the current sensor (5) from the battery tray. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor > Component Information > Locations > Page 2336 7. Remove the current sensor (2) from the battery negative cable (1). Installation Procedure 1. Install the current sensor (2) to the battery negative cable (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor > Component Information > Locations > Page 2337 2. Install the current sensor (5) to the battery tray. 3. Connect the wiring harness current sensor plug (4). 4. Install the battery negative cable (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the battery ground cable nut (1) and tighten to 9 Nm (80 lb in). 6. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 7. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Recalls for Body Control Module: > 10317 > Oct > 10 > Campaign Brake Apply Sensor Replacement Body Control Module: Recalls Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Recalls for Body Control Module: > 10317 > Oct > 10 > Campaign Brake Apply Sensor Replacement > Page 2346 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Recalls for Body Control Module: > 10317 > Oct > 10 > Campaign Brake Apply Sensor Replacement > Page 2347 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Body Control Module: All Technical Service Bulletins Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 2353 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 2354 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2355 Body Control Module: Locations Instrument Panel/Center Console Component Views Behind the Center of the I/P Components 1 of 4 1 - K9 Body Control Module 2 - X7 Body Control Module X7 3 - X6 Body Control Module X6 4 - X5 Body Control Module X5 5 - X4 Body Control Module X4 6 - X3 Body Control Module X3 7 - X2 Body Control Module X2 8 - X1 Body Control Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2356 Body Control Module: Diagrams Component Connector End Views K9 Body Control Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2357 K9 Body Control Module X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2358 K9 Body Control Module X3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2359 K9 Body Control Module X4 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2360 K9 Body Control Module X5 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2361 K9 Body Control Module X6 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2362 K9 Body Control Module X7 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2363 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Body Control Module Replacement Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Body Control Module Replacement > Page 2366 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle Camshaft Position Sensor: Customer Interest Engine - Lack of Power with Multiple DTCs or Rattle TECHNICAL Bulletin No.: 10-06-04-016 Date: December 20, 2010 Subject: Engine Lack of Power with DTCs P0011, P0014, P000A, P000B, P0012, P0015 or Engine Rattle Noise (Remove Oil Filters from Intake and Exhaust Camshaft Position Actuator Solenoid Valves) Models: 2008-2011 Chevrolet Aveo 2011 Chevrolet Cruze (US and Canada) 2009-2011 Chevrolet Cruze (Export Only) 2008-2009 Pontiac G3, Wave 2008-2009 Saturn Astra Condition Some customers may comment on lack of power with the following DTCs or an engine rattle noise from the sprockets. Cruze GEN3 1.6/1.8D - P0011: Intake Camshaft Position (CMP) System Performance - P0014: Exhaust Camshaft Position (CMP) System Performance - P000A: Intake Camshaft Position System Slow Response - P000B: Exhaust Camshaft Position System Slow Response Aveo GEN3 1.4D - P0012: Intake Camshaft Position (CMP) System Performance Bank 1-Retarded - P0015: Exhaust Camshaft Position (CMP) System Performance Bank 1-Retarded Aveo/G3/Wave Gen3 1.6D - P0011: Intake Camshaft Position (CMP) System Performance Bank 1 - P0014: Exhaust Camshaft Position (CMP) System Performance Bank 1 Correction Remove four oil filters from the intake and exhaust camshaft position actuator solenoid valves. 1. Open the hood. 2. Disconnect the negative battery cable. 3. Disconnect the camshaft position actuator solenoid valve connectors. 4. Remove the power steering line bracket bolt and reposition the bracket (for 1.6/1.8L only). 5. Disconnect PCV pipe and reposition (for 1.6/1.8L only). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 2375 6. Remove the camshaft position actuator solenoid valve bolts. 7. Remove the camshaft position actuator solenoid valves and seals. 8. Check whether the filter is broken or not (1). 9. Remove the four filters (intake and exhaust). 1. Broken Filter: Remove filter with a blunt tool. 2. Unbroken Filter 1. Locate the filter hinge between the holes. 2. Cut the filter hinge slightly. Caution Do not scratch the valve surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 2376 3. Remove the filter with a blunt tool. 10. Install the camshaft position actuator solenoid valves and seals. Coat the seal with clean engine oil prior to installation. 11. Install the camshaft position actuator solenoid valve bolts. Tighten Tighten the bolts to 6 Nm (53 lb in). 12. Connect the camshaft position actuator solenoid valve connectors. 13. Reposition and install the PCV pipe (for 1.6/1.8 only). 14. Reposition the power steering bracket and install the power steering line bracket bolt (for 1.6/1.8 only). 15. Connect the negative battery cable. Note If an engine rattle noise is heard after removing the filters, refer to SI for further diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle Camshaft Position Sensor: All Technical Service Bulletins Engine - Lack of Power with Multiple DTCs or Rattle TECHNICAL Bulletin No.: 10-06-04-016 Date: December 20, 2010 Subject: Engine Lack of Power with DTCs P0011, P0014, P000A, P000B, P0012, P0015 or Engine Rattle Noise (Remove Oil Filters from Intake and Exhaust Camshaft Position Actuator Solenoid Valves) Models: 2008-2011 Chevrolet Aveo 2011 Chevrolet Cruze (US and Canada) 2009-2011 Chevrolet Cruze (Export Only) 2008-2009 Pontiac G3, Wave 2008-2009 Saturn Astra Condition Some customers may comment on lack of power with the following DTCs or an engine rattle noise from the sprockets. Cruze GEN3 1.6/1.8D - P0011: Intake Camshaft Position (CMP) System Performance - P0014: Exhaust Camshaft Position (CMP) System Performance - P000A: Intake Camshaft Position System Slow Response - P000B: Exhaust Camshaft Position System Slow Response Aveo GEN3 1.4D - P0012: Intake Camshaft Position (CMP) System Performance Bank 1-Retarded - P0015: Exhaust Camshaft Position (CMP) System Performance Bank 1-Retarded Aveo/G3/Wave Gen3 1.6D - P0011: Intake Camshaft Position (CMP) System Performance Bank 1 - P0014: Exhaust Camshaft Position (CMP) System Performance Bank 1 Correction Remove four oil filters from the intake and exhaust camshaft position actuator solenoid valves. 1. Open the hood. 2. Disconnect the negative battery cable. 3. Disconnect the camshaft position actuator solenoid valve connectors. 4. Remove the power steering line bracket bolt and reposition the bracket (for 1.6/1.8L only). 5. Disconnect PCV pipe and reposition (for 1.6/1.8L only). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 2382 6. Remove the camshaft position actuator solenoid valve bolts. 7. Remove the camshaft position actuator solenoid valves and seals. 8. Check whether the filter is broken or not (1). 9. Remove the four filters (intake and exhaust). 1. Broken Filter: Remove filter with a blunt tool. 2. Unbroken Filter 1. Locate the filter hinge between the holes. 2. Cut the filter hinge slightly. Caution Do not scratch the valve surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 2383 3. Remove the filter with a blunt tool. 10. Install the camshaft position actuator solenoid valves and seals. Coat the seal with clean engine oil prior to installation. 11. Install the camshaft position actuator solenoid valve bolts. Tighten Tighten the bolts to 6 Nm (53 lb in). 12. Connect the camshaft position actuator solenoid valve connectors. 13. Reposition and install the PCV pipe (for 1.6/1.8 only). 14. Reposition the power steering bracket and install the power steering line bracket bolt (for 1.6/1.8 only). 15. Connect the negative battery cable. Note If an engine rattle noise is heard after removing the filters, refer to SI for further diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Disassembled Views Camshaft Position Sensor: Locations Disassembled Views Disassembled Views Engine Front Cover And Oil Pump Assembly (1 of 2) 1 - Camshaft Position Actuator Solenoid Valve Bolt 2 - Intake Camshaft Position Actuator Solenoid Valve 3 - Exhaust Camshaft Position Actuator Solenoid Valve 4 - Intake Camshaft Position Sensor Bolt 5 - Intake Camshaft Position Sensor 6 - Intake Camshaft Position Sensor Seal Ring 7 - Engine Front Cover 8 - Engine Front Cover Gasket 9 - Exhaust Camshaft Position Sensor Seal Ring 10 Exhaust Camshaft Position Sensor 11 - Exhaust Camshaft Position Sensor Bolt 12 - Engine Front Cover Oil Gallery Plug 13 - Engine Front Cover Oil Gallery Plug Seal Ring 14 - Oil Pressure Relief Valve Piston 15 - Oil Pressure Relief Valve Spring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2386 16 - Oil Pressure Relief Valve Plug 17 - Engine Front Cover Bolt (M10) 18 - Crankshaft Front Oil Seal 19 - Engine Front Cover Bolt (M6) 20 - Water Drain Plug Seal Ring 21 - Water Drain Plug 22 Exhaust Camshaft Position Actuator Solenoid Valve Bolt Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2387 Camshaft Position Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Front (LUJ) 1 - Q6E Camshaft Position Actuator Solenoid Valve - Exhaust 2 - B23E Camshaft Position Sensor Exhaust 3 - B37 Engine Oil Pressure Switch 4 - B52A Heated Oxygen Sensor 1 5 - Q42 Turbocharger Wastegate Solenoid Valve 6 - Q2 A/C Compressor Clutch Engine Components - Right Rear (LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2388 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2389 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Open hood. Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 2. Disconnect the camshaft position sensor wiring harness plug (1). Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 3. Remove the camshaft position sensor bolt (3). 4. Remove the camshaft position sensor (2) and the seal ring (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2390 Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 1. Install the camshaft position sensor (2) and the seal ring (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 2. Install the camshaft position sensor bolt (3) and tighten to 8 Nm (71 lb in). Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 3. Connect the camshaft position sensor wiring harness plug (1). 4. After replacement of an camshaft position sensor, use a scan tool to speed up learn function. Refer to Engine Control Module Programming and Setup (LUW, LUJ) (See: Testing and Inspection/Programming and Relearning/Engine Control Module Programming and Setup) 5. Close hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Powertrain Component Views Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Powertrain Component Views Engine Components - Left Rear (LUJ) 1 - B111 Turbocharger Boost Pressure Sensor 2 - T8 Ignition Coil 3 - B68 Knock Sensor (KS) 4 Q38 Throttle Body 5 - B34 Engine Coolant Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Powertrain Component Views > Page 2395 Coolant Temperature Sensor/Switch (For Computer): Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components 1 - G105 Engine Compartment - Front Left 2 - G10 Cooling Fan Motor 3 - B34B Engine Coolant Temperature Sensor 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Engine Coolant Temperature Sensor Replacement (Radiator) Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement (Radiator) Engine Coolant Temperature Sensor Replacement (Radiator) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Engine Coolant Temperature Sensor Replacement (Radiator) > Page 2398 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement (Water Outlet) Engine Coolant Temperature Sensor Replacement (Water Outlet) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views Crankshaft Position Sensor: Locations Disassembled Views Disassembled Views Engine Block Assembly - 1.4L LDD 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Engine Block 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2403 16 - Oil Pan Bolt 17 - Oil Pan Drain Plug Seal Ring 18 - Oil Pan Drain Plug 19 - Crankshaft Position Sensor Bolt 20 - Crankshaft Position Sensor 21 - Crankshaft Position Sensor Seal Ring 22 Crankshaft Bearing Cap Tie Plate Bolt (M8) 23 - Crankshaft Position Sensor Reluctor Ring 24 Flywheel Bolt 25 - Engine Flywheel 26 - Crankshaft Rear Oil Seal 27 - Crankshaft Position Sensor Reluctor Ring Bolt 28 - Connecting Rod Bearing Cap Bolt 29 - Connecting Rod Bearing Cap 30 Lower Connecting Rod Bearing 31 - Upper Connecting Rod Bearing 32 - Connecting Rod 33 Piston Pin 34 - Piston 35 - Piston Oil Ring (With oil Ring Spacer) 36 - Lower Compression Ring 37 - Upper Compression Ring Engine Block Assembly - 1.4L LUH and LUJ Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2404 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Cylinder Head 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Baffle 16 - Oil Pan Baffle Bolt 17 - Oil Pan 18 - Oil Pan Bolt 19 - Oil Pan Drain Plug 20 - Crankshaft Position Sensor Bolt 21 - Crankshaft Position Sensor 22 - Crankshaft Position Sensor Seal Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2405 23 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 24 - Piston Oil Nozzle 25 - Crankshaft Position Sensor Reluctor Ring 26 - Crankshaft Position Sensor Reluctor Ring Bolt 27 - Crankshaft Rear Oil Seal 28 - Engine Flywheel (Two-Mass) 29 - Engine Flywheel Bolt 30 - Connecting Rod Bearing Cap Bolt 31 - Connecting Rod Bearing Cap 32 - Lower Connecting Rod Bearing 33 - Upper Connecting Rod Bearing 34 - Connecting Rod 35 - Piston Pin 36 - Piston Pin Retainer 37 - Piston Pin Retainer 38 - Piston 39 - Piston Oil Ring (With Oil Ring Spacer) 40 - Lower Compression Ring 41 - Upper Compression Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2406 Crankshaft Position Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Rear (LUJ) 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2407 Crankshaft Position Sensor: Diagrams Component Connector End Views B26 Crankshaft Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2408 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The crankshaft position sensor system variation learn procedure is required when the following service procedures have been performed, regardless of whether DTC P0315 00 is set: * Engine replacement * Engine control module (ECM) replacement * Crankshaft damper replacement * Crankshaft replacement * Crankshaft Position Sensor Replacement * Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Note: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the crankshaft position sensor system variation learn procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * Crankshaft Position Sensor activity - If there is a crankshaft position sensor condition, refer to the applicable DTC that set. * Camshaft position signal activity - If there is a camshaft position sensor signal condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT) - If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P0315 00, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select the Crankshaft Position System Variation Learn procedure and perform the following: 1. Observe the fuel cut-off for the applicable engine. 2. Block the drive wheels. 3. Set the parking brake. 4. Place the vehicles transmission in Park or Neutral. 5. Turn the air conditioning (A/C) OFF. 6. Cycle the ignition from OFF to ON. 7. Apply and hold the brake pedal for the duration of the procedure. 8. Start and idle the engine. 9. Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 10. Release the throttle when fuel cut-off occurs. ‹› Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC P0315 00 ran and passed, the crankshaft position sensor variation learn procedure is complete. If the scan tool indicates DTC P0315 00 failed or did not run, refer to DTC P0315 (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 5. Turn OFF the ignition for 30 s after the learn procedure is completed successfully. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2409 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 2 of 2 1 - X84 Data Link Connector Lower Left of the I/P Components Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2413 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2414 Data Link Connector: Diagrams Component Connector End Views X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Description and Operation Electronic Throttle Actuator: Description and Operation Throttle Actuator Control (TAC) System Description Circuit/System Description The engine control module (ECM) is the control center for the throttle actuator control (TAC) system. The ECM determines the drivers intent based on input from the accelerator pedal position sensors, then calculates the appropriate throttle response based on the throttle position sensors. The ECM achieves throttle positioning by providing a pulse width modulated voltage to the throttle actuator motor. The throttle blade is spring loaded in both directions, and the default position is slightly open. Modes Of Operation Normal Mode During the operation of the TAC system, several modes, or functions, are considered normal. The following modes may be entered during normal operations: * Minimum pedal value - At key up, the ECM updates the learned minimum pedal value. * Minimum throttle position values - At key up, the ECM updates the learned minimum throttle position value. In order to learn the minimum throttle position value, the throttle blade is moved to the closed position. * Ice break mode - If the throttle blade is not able to reach a predetermined minimum throttle position, the ice break mode is entered. During the ice break mode, the ECM commands the maximum pulse width several times to the throttle actuator motor in the closing direction. * Battery saver mode - After a predetermined time without engine RPM, the ECM commands the battery saver mode. During the battery saver mode, the throttle body TAC module removes the voltage from the motor control circuits, which removes the current draw used to maintain the idle position and allows the throttle to return to the spring loaded default position. Reduced Engine Power Mode When the ECM detects a condition with the TAC system, the ECM may enter a reduced engine power mode. Reduced engine power may cause one or more of the following conditions: * Acceleration limiting - The ECM will continue to use the accelerator pedal for throttle control, however, the vehicle acceleration is limited. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Description and Operation > Page 2418 * Limited throttle mode - The ECM will continue to use the accelerator pedal for throttle control, however, the maximum throttle opening is limited. * Throttle default mode - The ECM will turn OFF the throttle actuator motor, and the throttle will return to the spring loaded default position. * Forced idle mode - The ECM will perform the following actions: - Limit engine speed to idle positioning the throttle position, or by controlling the fuel and spark if the throttle is turned OFF. - Ignore the accelerator pedal input. * Engine shutdown mode - The ECM will disable fuel and deenergize the throttle actuator. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues Engine Control Module: Recalls Campaign - Thermostat Sticks Open Causes Shift Issues SERVICE UPDATE Bulletin No.: 10399A Date: December 02, 2010 Subject: 10399A - Service Update for Inventory and Customer Vehicles - Powertrain Improvements - Thermostat Sticks in Open Position and Shift Quality - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with a 1.4L Turbo Engine (LUJ) Supercede: The Subject and Purpose in this bulletin are being revised to advise that the new ECM calibration will also address shift quality issues.Please discard all copies of bulletin 10399, issued November 2010. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to reprogram the engine control module (ECM) on certain 2011 model year Chevrolet Cruze vehicles equipped with a 1.4L turbo engine (LUJ). These vehicles may have a condition where the thermostat sticks in the open position. If this occurs, diagnostic codes will be set and the Service Vehicle Soon light/message will illuminate. These vehicles may also have transmission shift quality issues due to calibration values. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. Additionally, a list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should also be checked for vehicle eligibility. Parts Information No parts are required for this update. Service Procedure Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 11/29/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming. 2. Reprogram the engine control module (ECM) and transmission control module (TCM) in sequence. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI or Tech 2(R) to the vehicle. If using MDI, connect to programming terminal with the cable (USB or LAN). 2. Select J-2534 MDI or J-2534 Tech 2(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues > Page 2427 3. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. 4. Follow the on-screen instructions. 3. Clear all DTCs using the GDS or Tech 2(R). Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Engine Control Module: Recalls Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 2432 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 2433 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues Engine Control Module: All Technical Service Bulletins Campaign - Thermostat Sticks Open Causes Shift Issues SERVICE UPDATE Bulletin No.: 10399A Date: December 02, 2010 Subject: 10399A - Service Update for Inventory and Customer Vehicles - Powertrain Improvements - Thermostat Sticks in Open Position and Shift Quality - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with a 1.4L Turbo Engine (LUJ) Supercede: The Subject and Purpose in this bulletin are being revised to advise that the new ECM calibration will also address shift quality issues.Please discard all copies of bulletin 10399, issued November 2010. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to reprogram the engine control module (ECM) on certain 2011 model year Chevrolet Cruze vehicles equipped with a 1.4L turbo engine (LUJ). These vehicles may have a condition where the thermostat sticks in the open position. If this occurs, diagnostic codes will be set and the Service Vehicle Soon light/message will illuminate. These vehicles may also have transmission shift quality issues due to calibration values. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. Additionally, a list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should also be checked for vehicle eligibility. Parts Information No parts are required for this update. Service Procedure Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 11/29/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming. 2. Reprogram the engine control module (ECM) and transmission control module (TCM) in sequence. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI or Tech 2(R) to the vehicle. If using MDI, connect to programming terminal with the cable (USB or LAN). 2. Select J-2534 MDI or J-2534 Tech 2(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues > Page 2439 3. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. 4. Follow the on-screen instructions. 3. Clear all DTCs using the GDS or Tech 2(R). Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 2444 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Engine Control Module: All Technical Service Bulletins Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 2449 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 2450 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 2455 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 2456 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 2457 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 2463 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 2468 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 2469 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 2470 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2471 Engine Control Module: Description and Operation Engine Control Module Description The engine control module (ECM) interacts with many emission related components and systems, and monitors the emission related components and systems for deterioration. OBD II diagnostics monitor the system performance and a diagnostic trouble code (DTC) sets if the system performance degrades. The malfunction indicator lamp (MIL) operation and the DTC storage are dictated by the DTC type. A DTC is ranked as a type A or type B if the DTC is emissions related. Type C is a non emissions related DTC. The ECM is located in the engine compartment. The ECM is the control center of the engine controls system. The ECM controls the following components: * The fuel injection system * The ignition system * The emission control systems * The on-board diagnostics * The A/C and fan systems * The throttle body motor system The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect the vehicle performance and the emissions. The ECM also performs diagnostic tests on various parts of the system. The ECM can recognize operational conditions and alert the driver via the MIL. When the ECM detects a malfunction, the ECM stores a DTC. The condition area is identified by the particular DTC that is set. This helps the technician in making repairs. ECM Function The engine control module (ECM) can supply 5 V or 12 V to the various sensors or switches. This is done through pull-up resistors to the regulated power supplies within the ECM. In some cases, even an ordinary shop voltmeter will not give an accurate reading because the resistance is too low. Therefore, a DMM with at least 10 Mohm input impedance is required in order to ensure accurate voltage readings. The ECM controls the output circuits by controlling the ground or the power feed circuit through the transistors or a device called an output driver module. EEPROM The programmable read only memory (EEPROM), which can be erased electronically, is a permanent memory that is physically part of the engine control module (ECM). The EEPROM contains program and calibration information that the ECM needs in order to control the powertrain operation. Special equipment, as well as the correct program and calibration for the vehicle, are required in order to reprogram the ECM. ECM Default Actions When a malfunction occurs within the engine control system, the engine control module (ECM) maintains control of the system with default actions. Default actions are calculated values, and/or calibrated default values, that are stored within the ECM. A certain level of engine performance is possible when a malfunction occurs dependant on the default actions taken. The ECM default actions prevent a complete loss of engine performance. ECM Output Controls The scan tool can control certain solenoids, valves, motors, and relays. The output controls can be found under the special functions selection of the scan tool. Some output controls may be disabled by the engine control module (ECM) during certain types of vehicle operation. Data Link Connector (DLC) The data link connector (DLC) is a 16-pin connector that provides the technician with a means of accessing serial data for aid in the diagnosis. This connector allows the technician to use a scan tool in order to monitor the various serial data parameters, and display the DTC information. The DLC is located inside the drivers compartment, underneath the dash. Malfunction Indicator Lamp (MIL) The malfunction indicator lamp (MIL) is located on the instrument panel cluster, or the driver information center. The MIL is controlled by the engine control module (ECM) and illuminates when the ECM detects a condition that affects the vehicle emissions. ECM Service Precautions Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2472 The engine control module (ECM), by design, can withstand the normal current draws that are associated with the vehicle operations. However, care must be taken in order to avoid overloading any of these circuits. When testing for opens or shorts, do not ground or apply voltage to any of the ECM circuits unless the diagnostic procedure instructs you to do so. These circuits should only be tested with a DMM. Aftermarket (Add-On) Electrical And Vacuum Equipment Caution: Do not attach add-on vacuum operated equipment to this vehicle. The use of add-on vacuum equipment may result in damage to vehicle components or systems. Caution: Connect any add-on electrically operated equipment to the vehicle's electrical system at the battery (power and ground) in order to prevent damage to the vehicle. Aftermarket, add-on, electrical and vacuum equipment is defined as any equipment installed on a vehicle after leaving the factory that connects to the vehicles electrical or vacuum systems. No allowances have been made in the vehicle design for this type of equipment. Add-on electrical equipment, even when installed to these strict guidelines, may still cause the powertrain system to malfunction. This may also include equipment not connected to the vehicle electrical system, such as portable telephones and radios. Therefore, the first step in diagnosing any powertrain condition is to make sure all of the after-market electrical equipment is removed or disconnected from the vehicle. After this has been done and if the condition still exists, the condition may be diagnosed in the normal manner. Electrostatic Discharge (ESD) Damage Note: In order to prevent possible electrostatic discharge damage to the ECM, do not touch the connector pins on the ECM. The electronic components that are used in the control systems are often designed to carry very low voltage. The electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 V of static electricity can cause damage to some electronic components. By comparison, it takes as much as 4 000 V for a person to even feel the zap of a static discharge. There are several ways for a person to become statically charged. The most common methods of charging are by friction and by induction. An example of charging by friction is a person sliding across a car seat. Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground. Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage, therefore, it is important to exercise great care when handling and testing electronic components. Emission Control Information Label The underhood vehicle emissions control information label contains important emission specifications and setting procedures. This identifies the year, the manufacturing division of the engine, the displacement of the engine in liters, the class of the vehicle, and type of fuel metering system. There is also an illustrated emission components and vacuum hose schematic. This label is located in the engine compartment of every General Motors vehicle. If the label has been removed, it can be ordered from GM service parts operations (GMSPO). Underhood Inspection Note: This inspection is very important and must be done carefully and thoroughly. Perform a careful underhood inspection when performing any diagnostic procedure or diagnosing the cause of an emission test failure. This can often lead to repairing a condition without further steps. Use the following guidelines when performing an inspection: * Inspect all of the vacuum hoses for correct routing, pinches, cuts, or disconnects. * Inspect any hoses that are difficult to see. * Inspect all of the wires in the engine compartment for the following conditions: - Burned or chafed spots - Pinched wires - Contact with sharp edges - Contact with hot exhaust manifolds Basic Knowledge Required Caution: Lack of basic knowledge of this powertrain when performing diagnostic procedures could result in incorrect diagnostic performance or damage to powertrain components. Do not attempt to diagnose a powertrain problem without this basic knowledge. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2473 A basic understanding of hand tools is necessary in order to effectively use this section of the service manual. You must be familiar with some of the basics of engine operation and electrical diagnosis in order to use this section of the service manual. * Basic electrical circuits, You should have an understanding of basic electricity and know the meaning of voltage (V), current (A), and resistance (ohm). You should understand what happens in a circuit with an open or a shorted wire, and you should be able to identify a shorted or open circuit by using a digital multimeter (DMM). You should be able to read and understand a wiring diagram. * Use of digital multimeter, You should be familiar with the DMM, particularly the essential tool. You should be able to use the meter in order to measure the voltage (V), the resistance (ohm), the current (A), intermittent (minimum/maximum), and frequency (Hz). * Use of circuit testing tools, You should not use a test lamp to diagnose the engine controls system unless you are specifically instructed to do so. You should know how to use jumper wires in order to test the components and allow DMM readings without damaging the terminals. You should know how to use the J 35616 - Adapter Kit and use the kit whenever the diagnostic procedures call for front probing any connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2474 Engine Control Module: Service and Repair Engine Control Module Replacement Removal Procedure Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note: It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last engine oil change. 1. Prepare the engine control module for the replacement. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). 2. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 3. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 4. Disconnect the 2 wiring harness plug (2) from the engine control module (3). 5. Unclip the engine control module bracket (4) from the battery tray. 6. Remove the 4 nuts (1). 7. Remove the engine control module (3) from the engine control module bracket (4). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2475 1. Install the engine control module (3) to the engine control module bracket (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 4 nuts (1) and tighten to 9 Nm (80 lb in). 3. Clip the engine control module bracket (4) to the battery tray. 4. Connect the 2 wiring harness plug (2) to the engine control module (3). 5. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 6. Program the ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Wheels/Vehicle Underbody Component Views Fuel Tank Components 1 - B150 Fuel Tank Pressure Sensor 2 - A7 Fuel Pump and Level Sensor Assembly 3 - Q13 Evaporative Emission (EVAP) Vent Solenoid Valve Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2479 Fuel Level Sensor: Diagrams Component Connector End Views A7 Fuel Pump and Level Sensor Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2480 Fuel Level Sensor: Service and Repair Fuel Sender Assembly Replacement Removal Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning: Refer to Safety Goggles and Fuel Warning (See: Fuel Delivery and Air Induction/Service Precautions/Safety Goggles and Fuel Warning). Caution: Use care while handling the fuel sender to prevent damage and incorrect fuel level readings. 1. Remove the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Tank Fuel Pump Module Replacement). 2. Disconnect the fuel sender assembly wiring harness plugs (1). 3. Unclip the 2 fuel sender retainer pins. 4. Remove the fuel sender assembly (2). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2481 1. Install the fuel sender assembly (2). 2. Connect the fuel sender assembly wiring harness plugs (1). 3. Install the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Tank Fuel Pump Module Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations Wheels/Vehicle Underbody Component Views Fuel Tank Components 1 - B150 Fuel Tank Pressure Sensor 2 - A7 Fuel Pump and Level Sensor Assembly 3 - Q13 Evaporative Emission (EVAP) Vent Solenoid Valve Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2485 Fuel Tank Pressure Sensor: Diagrams Component Connector End Views B150 Fuel Tank Pressure Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Specifications Information Bus: Specifications Fastener Tightening Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2491 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2492 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2493 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2494 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2495 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2496 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2497 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2498 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2499 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2500 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2501 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2502 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2503 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2504 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2505 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2506 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2507 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2508 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2509 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2510 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2511 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2512 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2513 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2514 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2515 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2516 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2517 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2518 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2519 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2520 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2521 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2522 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2523 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2524 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2525 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2526 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2527 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2528 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2529 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2530 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2531 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2532 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2533 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2534 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2535 Information Bus: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2536 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2537 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2538 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools EL-35616-200 - Test Light - Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A Digital Multimeter (DMM) should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The EL-35616-200 - kit is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2539 Testing for a Short to Voltage Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J-25070 - Heat Gun For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, to move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to the Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J-25070 - heat gun. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2540 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. In addition, circuit cooling spray can be used to cool down a component or circuit. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2541 For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Special Tools Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2542 EL-35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2543 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Using Snapshots in Global Diagnostic System (GDS) Overview Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2544 A snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. To record a snapshot in GDS, select, Record Snapshot, from the options at the top right portion of any of the various pages that allow snapshots to be taken (e.g. Data Display, Control Functions, etc.). When you are finished recording, select, Stop Snapshot recording. The snapshot will now be available for replay. Snapshot Replay The Snapshot Replay function allows reviews of previously recorded vehicle snapshot data. This information can be used in analysis of vehicle problems and detection of trigger error conditions. The graph function can be used to compare parameters to see if a component is functioning properly. Recorded snapshots can be selected for viewing by the following three methods: * Selecting a snapshot file from the Vehicle Home Page and clicking on the Review selection. * Double clicking on the selected snapshot from the Vehicle Home Page. * Entering the Tools selection from the Menu selection and selecting Snapshot replay. Next, open the Snapshot Manager. Double click on the snapshot file you wish to view or click on the Load Snapshot selection and select a snapshot file. Regardless of selection method, a File Loaded pop-up window will be displayed from the Snapshot Replay screen. Select OK from the pop-up window. Snapshot Play Functions There are several snapshot play functions that are used to replay recorded snapshots * The Play function is used to play the snapshot forward by clicking on this selection. A marker will move across the screen when this selection is used. All selections in this area turn grey when they are active. * The Pause function is used to pause play of the snapshot. When this selection is clicked a second time the snapshot will start playing where it left off. * The Stop function is used to stop playing the snapshot. The snapshot will start from the beginning, if Play is selected after using the Stop function. Time Control Time control is used to control the snapshot replay. This function allows selection of a specific time frame, display of different views, and control of display speed. The following functions can be selected directly under Time Control. * The Bookmark selection allows you to add a specific comment in the current display and return to this point in the future. When this option is selected, a pop-up window is displayed. Enter a bookmark name and select OK. * The Note Pad can be selected to add comments to the snapshot replay file at the current point of time. When this option is selected, a pop-up window is displayed. Enter a comment for the snapshot file and select OK. * The Load Snapshot (blue folder) opens a snapshot file and makes it ready for further analysis. This function is also available by clicking on an available snapshot file from the Snapshot Manager. * The Down Arrow displays all Time Control options when selected. Individual options can also be selected by clicking on the item you want. * The Snapshot Display Speed can be controlled by selecting this option. Slow speeds of 1/8X, 1/4X, and 1/2X can be selected. The real time speed can also be selected at 1. Faster speeds of 2X, 4X, and 8X can also be obtained by using this selection. View Selections Each View Selection provides a different way of displaying vehicle data for analysis. The following functions can be selected under Available Views: Note: The parameter name will be shown in the original language used for capture if no translation is available for the name. * Parameter List View - Displays incoming information from the snapshot file. The current value of the parameters is displayed on the screen. * Log View - Contains all the information from the snapshot file. All parameter values are listed in the order they were recorded. Specific parameters can be added or removed from a watchlist by clicking on the appropriate item. * State View - Shows the values of all parameters in a specific time frame. These values can be used for comparison with the trigger view. * Trigger View - Displays all system and user defined triggers. This function can be used when there is a combination of factors involved in a diagnostic problem. When a Trigger condition is met a caution triangle will be displayed on the screen. Triggers: * Load Triggers - Allows you to load a file containing trigger definitions. * Save Triggers - Allows you to save the trigger to your computer's hard drive. * Remove Trigger - Allows you to remove the current trigger. It will no longer be present. * Edit Trigger - Displays a pop-up window where you can modify the limits and parameters contained within a trigger. * Adds Trigger - Displays a pop-up window to configure a trigger. * DTC View - After the Play function is selected and this option is selected this function opens the list of recorded DTCs. * Line Graph View - Displays data that can be visualized against the time-axis. From this view, specific parameters can be selected for graphing by Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2545 checking the box under Selected. At the bottom of the graph there are four functions Zoom In (increase size), Zoom Out (decrease size), Bookmarks, and Pause Scrolling. Each of these functions can be accessed by clicking on them. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools EL-39200 - Digital Multimeter For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the EL-39200 - digital multimeter (DMM). This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. Note: The DMM must be used in order to perform the following procedure since the DMM can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2546 Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the DMM to the circuit. 2. Set the DMM to the V (AC) or V (DC) position. 3. Select the voltage range feature of the DMM in order to select the desired voltage range. Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 4. Select the MIN MAX function of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button until the MAX value is displayed and note the value. 8. Press the MIN MAX button until the MIN value is displayed and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools EL-35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2547 To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the EL-35616 - kit when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center. Use EL-35616 - kit to test for proper terminal contact. Failure to use EL-35616 - kit can result in improper diagnosis of the bussed electrical center. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal/terminated lead, verify that the retention force is significantly different between a known good terminal and the suspect terminal. Replace the female terminal in question. Flat Wire Connectors There are no serviceable parts for flat wire connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter into the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2548 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures - In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference or other types of electrical noise. Inspect for the following conditions: * A mis-routed harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc.-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc.-These accessories may create interference in other circuits while operating and the interference would disappear when the accessory is not operating. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2549 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, current, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 Mohm input impedance 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Current 1. Test a DC current range of 0.1 µA-10 A. 2. Test an AC current range of 0.1 µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 Mohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 Hz-199 k Hz Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2550 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 25 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the engine control module (ECM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the EL-39200. The DMM instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Special Tools EL 35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools EL 35616-20F - Fused Jumper Wire For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: A fused jumper may not protect solid state components from being damaged. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2551 The EL 35616-20F - Fused Jumper Wire includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool * J-38125-216 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2552 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2553 3. Slide the lever lock forward while pressing down on the lever lock release tab. 4. View showing depressing of the lever lock release tab. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2554 5. View of connector in released position. 6. Disconnect the connector from the component. 7. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 8. Release the rear lower half of the wiredress cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2555 9. Release the tabs that are holding the wiredress cover to the connector body. 10. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J-38125-216 can also be used to remove the nose piece. 11. Use the J-38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2556 12. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 13. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 14. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-561 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2557 4. Insert the J-38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-213 - Terminal Release Tool * J-38125-556 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2558 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2559 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2560 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J-38125-213 or the J-38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. 10. Reconnect the connector bodies. Bosch Connectors (0.64) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2561 Bosch Connectors (0.64) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2562 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2563 11. Insert the J-38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 13. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 14. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2564 Bosch Connectors (2.8 JPT) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-557 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J-38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2565 * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT) )Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock))FCI Connectors (SIR) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI (SIR)) * FEP Connectors (Steering Gear) (See: General Electrical Diagnostic Procedures/Connector Repairs/FEP Connectors (Steering Gear)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) Connector Anatomy Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2566 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2567 * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2568 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2569 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2570 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2571 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools EL-38125-580 - Terminal Release Tool Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2572 Terminal Removal Procedure Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull to Seat) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2573 Delphi Connectors (Pull To Seat) Special Tools EL-38125-580 - Terminal Release Tool Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Review the connector end view to determine the proper test probe and release tool. 5. Insert the release tool into the front of the connector body. 6. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 3. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-21 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2574 Terminal Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2575 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2576 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wire dress cover and pull the lever over and past the locks. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2577 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2578 Note: Be careful not to angle or rock the J-38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J-38125-21 tool into the round canal between the terminals cavities at the front of the connector. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2579 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2580 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2581 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2582 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J-38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2583 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-10A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J-38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2584 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (12-Way) Delphi Connectors (12-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2585 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2586 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2587 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J-38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2588 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (Steering Gear) Delphi Connectors (Steering Gear) Removal Procedure 1. Use a small flat-bladed tool to release the locking tab on the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2589 2. Push down the locking tab to release the connector. The small flat-bladed tool may need to be pushed down and angled back slightly to depress the locking tab. Pull on the connector body while releasing the locking tab to disconnect the connector. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-556 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2590 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2591 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. 7. For the larger terminals insert the J-38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J-38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2592 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 9. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 10. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. FCI (SIR) FCI Connectors (SIR) Removal Procedure Note: The orange connector position assurance (CPA) must be released first to disconnect or to connect the connector. 1. Lift the orange CPA vertically (avoid lifting on an angle to the connector) approximately 4 mm to release the connector. Use a small flat-bladed Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2593 tool to help release the orange CPA. The orange CPA can also be released manually without any tools. 2. Grab the connector on both sides and lift the connector vertically to disconnect the connector. Installation Procedure 1. Lift the orange CPA vertically approximately 4 mm before installing the connector. Use a small flat-bladed tool to help release the orange CPA. The orange CPA can also be released manually without any tools. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2594 2. Line up the connector key tabs with the initiator key slots. Grab the connector on both sides and push the connector down into the initiator connector sub assembly until fully seated. 3. After the connector is fully seated, push down the orange CPA with your thumb. Push down until the orange CPA is touching the yellow cover on the connector. FEP Connectors (Steering Gear) FEP Connectors (Steering Gear) Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2595 1. Use a small flat-bladed tool to release the locking tab on the connector. 2. Push down the locking tab to release the connector. The small flat-bladed tool may need to be pushed down and angled back slightly to depress the locking tab. Pull on the connector body while releasing the locking tab to disconnect the connector. JST Connectors JST Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2596 The JST connector family consists of seven unique connector housings differentiated by color and keying. This connector family is designed to use both 0.64 and 2.8 sized terminals. 1. While depressing the lock, remove the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2597 2. Unlock the terminal position assurance (TPA): * Position connector as shown (above) and locate TPA staging cavities. * Using connector terminal release tool J-38125-553 (1) lift the TPA into the staged position (figure 1). Perform this step on both sides of the TPA. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2598 * You will feel the TPA click into place when fully extended into the staged position. The figure above shows the TPA (1) in the staged position. 3. Release the terminal from the connector: * Position the connector as shown (above) and locate the terminal release entry canal (1) of the suspect terminal. * Insert the connector terminal release tool J-38125-553 into the entry canal with the angled side of the tool facing the connector wall containing cavity 4 (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2599 * The cavity on the left (1) is a 2.8 mm cavity and the cavity on the right (2) is a 0.64 mm cavity. * Place the tip of the connector terminal release tool onto the connector lance (3) and deflect the lance to the right (5) to release the lock. Hold this released position. * Holding the lance in the released position, slightly pull on the suspect terminal to remove it from the connector housing. The side TPA (4) is a secondary lock. 4. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 5. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-24 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2600 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2601 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2602 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2603 8. Use the J-38125-24 or the J-38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-28 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2604 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2605 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J-38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2606 locked in place by gently pulling on the wire. 3. Locate the TPA. 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2607 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-213 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2608 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2609 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2610 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J-38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2611 Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2612 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J-38125-12A - tool into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2613 7. Pressing the J-38125-12A - tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool * J-38125-13A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-bladed tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2614 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-bladed tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J-38125-13A - tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J-38125-12A - tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2615 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2616 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2617 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2618 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2619 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2620 6. Use the J-38125-12A tool to release the terminals by pressing on the tang. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool * J-38125-212 - Terminal Release Tool * J-38125-216 - Terminal Release Tool * J-38125-221 - Terminal Release Tool * J-38125-560 - Terminal Release Tool * J-38125-566 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2621 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2622 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2623 Note: During assembly the terminal position assurance (TPA) will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J-38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2624 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2625 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2626 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J-38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2627 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2628 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2629 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2630 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2631 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. 22. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 23. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool * J-38125-212 - Terminal Release Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2632 * J-38125-556 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2633 Note: Terminal position assurance (TPA) is keyed and can only be inserted in one direction. 3. Using terminal release tool J-38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2634 5. Using terminal release tool J-38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2635 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2636 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2637 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2638 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2639 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2640 * J-38125-552 - Terminal Release Tool * J-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2641 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2642 5. Once the nose piece retainers are relaxed, use the J-38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2643 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2644 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2645 2. Insert the J-38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2646 5. Insert the J-38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-24 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2647 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2648 5. While pushing the terminal forward, insert the J-38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2649 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J-38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2650 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-215 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2651 1. While depressing the lock, pull the two connector halves apart. Note: The terminal position assurance (TPA) is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the TPA towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2652 4. View of the female half of the connector with male terminals. 5. Use the J-38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. 6. View of the female half of the connector with male terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2653 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 9. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 10. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Repairing Connector Terminals (Terminated Lead Repair) Repairing Connector Terminals (Terminated Lead Repair) Special Tools * EL-38125-10 - Splice Sleeve Crimp Tool * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs procedures. For high temperature wiring repairs, refer to High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs). Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to in Splicing Copper Wire Using Splice Sleeves to identify the correct DuraSeal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Repairing Connector Terminals (Terminal Repair) Repairing Connector Terminals (Terminal Repair) Special Tools * J-38125 - Terminal Repair Kit * J-38125-6 - Crimp Tool * J-38125-7 - Crimp Tool * J-38125-8 - Crimp Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2654 * J-38125-64 - Crimp Tool * J-38125-101 - Crimp Tool * J-38125-641 - Crimp Tool * J-38125-642 - Crimp Tool * J-38125-643 - Crimp Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Use the following repair procedures to repair each type of terminal: * For push to seat terminals, refer to Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)). * For pull to seat terminals, refer to Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)). Note: The first step for all terminal repairs is to find the connector end view in SI. Cable Seal Terminals 1. Cut off the terminal between the core and the insulation crimp to minimize any wire loss. 2. Remove the old seal. 3. Apply the correct cable seal, per the wire gauge size, from the kit. Slide the seal back along the wire to enable removal of the insulation. 4. To minimize wire loss, remove only the insulation required. 5. Using the connector end view, determine the correct crimp tool and crimp jaw. 6. Align the seal with the end of the cable insulation. 7. Position the stripped wire and seal in the terminal. 8. Hand Crimp the core wings first. 9. Hand Crimp the insulation wings around the seal and the cable. 10. Solder all of the hand crimp terminals except the Micro-Pack 100 and 0.64 sizes. Unsealed Terminals 1. Cut off the terminal between the core and the insulation crimp to minimize any wire loss. 2. To minimize wire loss, remove only the insulation required. 3. Position the stripped wire in the terminal. 4. Hand Crimp the core wings first. 5. Hand Crimp the insulation wings around the cable. 6. Solder all of the hand crimp terminals except the Micro-Pack 100 and 0.64 sizes. Micro-Pack 100W Size Terminal The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2655 the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Micro 0.64 Size Terminal The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J-38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J-38125-64 crimping tool is also designed to crimp Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2656 both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2657 7. Place the terminal into the appropriate cavity and assemble the connector. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2658 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch Special Tool * DuraSeal splice sleeves * A wire stripping tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2659 For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Description and Operation). GMLAN Connector Terminal Repair Note: A terminated lead can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs in the service information connector end views or the vehicle schematics in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and EL-38125-10 - tool. For wiring repair, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. High Temperature Wiring Repairs High Temperature Wiring Repairs Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2660 Note: All wiring repairs need to be 200 mm from the heat zone. Areas of consideration would be any area located near the exhaust manifolds, catalytic converter, exhaust pipes, and turbocharged engines. Items Required * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * Terminated leads or pigtails * The correct tools to remove the terminals from the connectors Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing. * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Note: High temperature areas would be areas located near exhaust manifolds, catalytic converters, exhaust pipes, and turbocharged engines. Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2661 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. Terminated leads can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs in the service information connector end views or the vehicle schematics in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2662 the DuraSeal splice sleeves and EL-38125-10 - tool. For wiring repair, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). For connector position assurance (CPA), refer to Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks). For terminal position assurance (TPA), refer to Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks). Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except Tefzel and coaxial. Use DuraSeal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert to regional wiring gauge size. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. For high temperature wiring, slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2663 tubing will not interfere with the splice procedure. 5. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 6. Use the splice sleeve crimp tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 7. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 8. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 9. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4, 6 and 15 for the opposite end of the splice. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2664 10. Using the heat torch, apply heat to the crimped area of the barrel. 11. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. High Temperature Wiring Repairs Use the following procedures to perform high temperature wiring repairs: 1. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 2. Using the heat torch, apply heat to the high temperature heat shrink tubing. 3. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 4. Replace any reflective tape and clips that may have been removed during the repair. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2665 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2666 * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2667 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2668 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2669 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. Note: Some terminals have a lever that must be disengaged before the terminal can be released. * Insert the terminal release tool into the cavity. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2670 Special Tools * EL-38125-10 - Splice Sleeve Crimp Tool * EL-38125-580 - Terminal Release Tool Kit * J-38125-5 - Ultra Torch * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2671 (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2672 Information Bus: Electrical Diagrams Data Communication Schematics Low Speed GMLAN High Speed GMLAN Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2673 Chassis Expansion Bus Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2674 Enable Serial Data Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2675 Local Interconnect Network (LIN) Serial Data Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2676 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2677 Information Bus: Description and Operation Data Link Communications Description and Operation Note: This is an overview of different serial data buses used by GM control modules to communicate with each others. Use Data Communication Schematics (See: Diagrams/Electrical Diagrams) to find out which serial data buses are configured for a specific vehicle. Circuit Description There are many components in a vehicle that rely on information from other sources, transmit information to other sources, or both. Serial data communication networks provide a reliable, cost effective, way for various components of the vehicle to "talk" to one another and share information. GM uses a number of different communication buses to insure the timely and efficient exchange of information between control modules. When compared to each other, some of these buses are different in nature as far as speed, signal characteristics, and behavior. An example of this is the High Speed GMLAN and Low Speed GMLAN buses. On the other hand, when other buses are compared to each other they have similar characteristics and simply operate in parallel. In this case they are used to group together components which have high interaction. Examples are the High Speed GMLAN, Powertrain Expansion, and Chassis Expansion buses. This allows them to communicate with each other on a bus with reduced message congestion insuring faster and the more timely exchange of information than if all vehicle control modules were on a single bus. The majority of information that exists within a given network generally stays local; however some information will have to be shared on other networks. Control modules designated as Gateway's perform the function of transferring information between the various buses. A Gateway module is connected to at least 2 buses and will interact with each network according to its message strategy and transmission models. GMLAN provides the capability for a receiving control module to monitor message transmissions from other control modules in order to determine if messages of interest are not being received. The primary purpose is to allow reasonable default values to be substituted for the information no longer being received. Additionally, a control module may set a Diagnostic Trouble Code to indicate that the control module it is expecting information from is no longer communicating. High Speed GMLAN Circuit Description A High Speed GMLAN Bus is used where data needs to be exchanged at a high enough rate to minimize the delay between the occurrence of a change in sensor value and the reception of this information by a control device using the information to adjust vehicle system performance. The High Speed GMLAN serial data network consists of two twisted wires. One signal circuit is identified as GMLAN-High and the other signal circuit is identified as GMLAN-Low. At each end of the data bus there is a 120 ohm termination resistor between the GMLAN-High and GMLAN-Low circuits. Data symbols (1's and 0's) are transmitted sequentially at a rate of 500 Kbit/s. The data to be transmitted over the bus is represented by the voltage difference between the GMLAN-High signal voltage and the GMLAN-Low signal voltage. When the two wire bus is at rest the GMLAN-High and GMLAN-Low signal circuits are not being driven and this represents a logic "1". In this state both signal circuits are at the same voltage of 2.5 V. The differential voltage is approximately 0 V. When a logic "0" is to be transmitted, the GMLAN-High signal circuit is driven higher to about 3.5 V and the GMLAN-Low circuit is driven lower to about 1.5 V. The differential voltage becomes approximately 2.0 (+/- 0.5) V. Chassis High Speed GMLAN Circuit Description The GMLAN Chassis Expansion Bus is basically a copy of the High Speed GMLAN Bus except that its use is reserved for chassis components. This implementation splits message congestion between two parallel buses helping to insure timely message transmission and reception. Sometimes communication is required between the Chassis Expansion Bus and the primary High Speed GMLAN Bus. This is accomplished by using the Electronic Brake Control Module (EBCM) as the Gateway module. Since the High Speed GMLAN Chassis Expansion Bus and primary High Speed GMLAN Bus operate in the same manner, the diagnostics for each are similar. CAN Graphical Interface (CGI) Circuit Description This bus is used by the Entertainment sub-system to transfer high-rate display graphics between the Radio and the Info Display Module and/or Radio/HVAC Control. The electrical characteristics of the CAN Graphical Interface (CGI) Bus are very similar to the High Speed GMLAN Bus. The message strategy and construction of messages are different however. Sometimes communication is required between the CAN Graphical Interface Bus and the Low Speed GMLAN Bus. This is accomplished by using the Radio SilverBox as the Gateway module. Since the CAN Graphical Interface Bus and primary High Speed GMLAN Bus have similar electrical characteristics, the diagnostics for each are similar. In the case where the Info Display Module and Radio/HVAC Control are separate control modules the Info Display Module is responsible for passing information between the Radio and the Radio/HVAC Control. The Radio interfaces only with the Info Display Module and the Info Display Module then Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2678 communicates with the Radio/HVAC Control through a Local Interconnect Network (LIN) interface. A bus wake up signal will be generated by the Radio or by the Info Display Module when the system functionality is required. The communication function of the CAN Graphical Interface shall be enabled or disabled based on the voltage level of the Center Stack Wake. The network will stay awake as long as the circuit voltage is driven low, to less than 1.5 V. Communications are disabled with a high circuit voltage around 5.0 V. The Radio can execute a warm reset of the Info Display Module if the Info Display Module fails to respond to the Radio's request. The Center Stack Reset is a low-asserted pull down output (less than 1.5 V) from the Radio to the Info Display Module and has the same electrical characteristics as those for the Center Stack Wake signal defined above. Mid Speed GMLAN Circuit Description The Mid Speed GMLAN Bus is very similar to the High Speed GMLAN Bus except that it uses a slower transmission rate of 125 Kbit/s. This bus is intended for use where the system response time demands that a large amount of data be transmitted in a relatively short amount of time, such as updating a graphics display. As such it has usually been used for infotainment applications. Sometimes communication is required between the Low Speed GMLAN Bus and the Mid Speed GMLAN Bus. This is accomplished by using the Radio (Silverbox) as the Gateway module. Since the Mid Speed GMLAN Bus and primary High Speed GMLAN Bus operate in a similar manner, the diagnostics for each are similar. Low Speed GMLAN Circuit Description Low Speed GMLAN Bus is used in applications where a high data rate is not required which allows for the use of less complex components. It is typically used for operator controlled functions where the response time requirements are slower than those required for dynamic vehicle control. The Low Speed GMLAN Serial Data Network consists of a single wire, ground referenced bus with high side voltage drive. During on road vehicle operation data symbols (1's and 0's) are transmitted sequentially at the normal rate of 33.3 Kbit/s. For component programming only, a special high speed data mode of 83.3 Kbit/s may be used. Unlike the high speed dual wire networks, the single wire low speed network does not use terminating resistors at either end of the network. The data symbols to be transmitted over the bus are represented by different voltage signals on the bus. When the Low Speed GMLAN Bus is at rest and is not being driven, there is a low signal voltage of approximately 0.2 V. This represents a logic "1". When a logic "0" is to be transmitted, the signal voltage is driven higher to around 4.0 V or higher. Local Interconnect Network (LIN) Circuit Description The Local Interconnect Network (LIN) Bus consists of a single wire with a transmission rate of 10.417 Kbit/s. This bus is used to exchange information between a master control module and other smart devices which provide supporting functionality. This type of configuration does not require the capacity or speed of either a High Speed GMLAN Bus or Low Speed GMLAN Bus and is thus relatively simpler. The data symbols (1's and 0's) to be transmitted are represented by different voltage levels on the communication bus. When the LIN Bus is at rest and is not being driven, the signal is in a high voltage state of approximately Vbatt. This represents a logic "1". When a logic "0" is to be transmitted, the signal voltage is driven low to about ground (0.0 V). Communication Enable Circuit Description Control modules on GMLAN high speed type networks, excluding the Mid Speed GMLAN Bus and CAN Graphical Interface Bus, enable or disable communication based on the voltage level of this circuit. When the circuit voltage is high (around 12 V), communications are enabled. When the circuit is low, communications are disabled. The CAN Graphical Interface Bus is similar but uses different voltage levels. See description above for the CAN Graphical Interface Bus. Data Link Connector (DLC) The data link connector (DLC) is a standardized 16-cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: * Pin 1 Low speed GMLAN communications terminal * Pin 2 Class 2 communications terminal * Pin 3 Mid speed GMLAN serial bus (+) terminal * Pin 4 Scan tool power ground terminal * Pin 5 Common signal ground terminal * Pin 6 High speed GMLAN serial data bus (+) terminal * Pin 7 Keyword communications terminal * Pin 11 Mid speed GMLAN serial bus (-) terminal * Pin 12 Chassis high speed GMLAN serial bus (+) terminal * Pin 13 Chassis high speed GMLAN serial bus (-) terminal Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2679 * Pin 14 High speed GMLAN serial data bus (-) terminal * Pin 16 Scan tool power, battery positive voltage terminal Serial Data Reference The scan tool communicates over the various buses on the vehicle. When a scan tool is installed on a vehicle, the scan tool will try to communicate with every control module that could be optioned into the vehicle. If an option is not installed on the vehicle, the scan tool will display No Comm for that optional control module. In order to avert misdiagnoses of No Communication with a specific control module, refer to Data Link References (See: Testing and Inspection/Initial Inspection and Diagnostic Overview) for a list of control modules, the buses they communicate with, and the RPO codes for a specific control module. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview Data Link References This table identifies which serial data link that a particular module uses for in-vehicle data transmission. Some modules may use more than one data link to communicate. Some modules may have multiple communication circuits passing through them without actively communicating on that data link. This table is used to assist in correcting a communication malfunction. Not all modules listed will be applicable to all vehicles. Refer to the schematics to determine which modules apply. For the description and operation of these serial data communication circuits refer to Data Link Communications Description and Operation (See: Description and Operation). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2682 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2683 Information Bus: Symptom Related Diagnostic Procedures Symptoms - Data Communications Symptoms - Data Communications Note: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) before using the symptom tables in order to verify that all of the following are true: * There are no DTCs set. * The control modules can communicate via the serial data links. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Data Link Communications Description and Operation (See: Description and Operation). Visual/Physical Inspection * Inspect for aftermarket devices which could affect the operation of the systems. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: * Scan Tool Does Not Power Up (See: Scan Tool Does Not Power Up) * Scan Tool Does Not Communicate with High Speed GMLAN Device (See: Scan Tool Does Not Communicate with High Speed GMLAN Device) * Scan Tool Does Not Communicate with Low Speed GMLAN Device (See: Scan Tool Does Not Communicate with Low Speed GMLAN Device ) * Scan Tool Does Not Communicate with Chassis High Speed GMLAN Device (See: Scan Tool Does Not Communicate with Chassis High Speed GMLAN Device) Scan Tool Does Not Communicate with Chassis High Speed GMLAN Device Scan Tool Does Not Communicate with Chassis High Speed GMLAN Device Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2684 Circuit/System Description The GMLAN high speed chassis expansion bus functions the same as the GMLAN high speed bus, and the two buses operate in parallel. The expansion chassis bus was added to reduce message congestion on the primary high speed bus. Since the GMLAN high speed chassis bus and primary GMLAN high speed bus operate in the same manner, the diagnostics for each are the same. The serial data is transmitted on two twisted wires that allow speeds up to 500 Kb/s. The twisted pair is terminated with two 120 ohms resistors, one is internal to the engine control module (ECM) and the other can be a separate resistor in a connector assembly or in another control module. The resistors are used as the load for the High Speed GMLAN buss during normal vehicle operation. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level of approximately 2.5 V. Driving the lines to their extremes, adds one volt to the high speed GMLAN serial data bus (+) circuit and subtracts one volt from the high speed GMLAN serial data bus (-) circuit. If serial data is lost, control modules will set a no communication code against the non-communicating control module. Note that a loss of serial data DTC does not represent a failure of the module that set it. Diagnostic Aids * Sometimes, while diagnosing a specific customer concern or after a repair, you may notice a history U-code present. However, there is no associated "current" or "active" status. Loss-of-communication U-codes such as these can set for a variety of reasons. Many times, they are transparent to the vehicle operator and technician, and/or have no associated symptoms. Eventually, they will erase themselves automatically after a number of fault-free ignition cycles. This condition would most likely be attributed to one of these scenarios: - A control module on the data communication circuit was disconnected while the communication circuit is awake. - Power to one or more modules was interrupted during diagnosis - A low battery condition was present, so some control modules stop communicating when battery voltage drops below a certain threshold. - Battery power was restored to the vehicle and control modules on the communication circuit did not all re-initialize at the same time. - If a loss-of-communication U-code appears in history for no apparent reason, it is most likely associated with one of the scenarios above. These are all temporary conditions and should never be interpreted as an intermittent fault, causing you to replace a part. * Do not replace a control module reporting a U code. The U code identifies which control module needs to be diagnosed for a communication issue. * Communication may be available between the BCM and the scan tool with the high speed GMLAN serial data system inoperative. This condition is due to the BCM using both the high and low speed GMLAN systems. * An open in the DLC ground circuit terminal 5 will allow the scan tool to operate but not communicate with the vehicle. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. * Technicians may find various Local Area Network (LAN) communication Diagnostic Trouble Codes (DTC) and no low speed GMLAN communications with the scan tool. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. These conditions may be caused by the installation of an aftermarket navigation radio module (see bulletins). Some customers may comment of one or more of the following concerns: - Vehicle will not crank - Vehicle cranks but will not start - Vehicle stability enhancement system warning lights and messages - PRNDL gear indicator position errors Reference Information Schematic Reference * Data Communication Schematics (See: Diagrams/Electrical Diagrams) * Control Module References (See: Testing and Inspection/Programming and Relearning) Connector End View Reference Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2685 Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Description and Operation Data Link Communications Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Testing Note: Each control module may need to be disconnected to isolate a circuit fault. Use the schematic to identify the following: * Control modules the vehicle is equipped with * Chassis high speed GMLAN serial data circuit terminating resistors * Control module locations on the chassis high speed GMLAN serial data circuits * Each control module chassis high speed GMLAN serial data circuit terminals 1. Attempt to communicate with all control modules on the high speed GMLAN serial data circuit. Refer to Data Link References (See: Initial Inspection and Diagnostic Overview). Communications should not be available with two or more control modules on the chassis high speed GMLAN serial data circuit. ‹› If only one control module is not communicating, diagnose that control module only. Refer to DTC U0100-U02FF (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts). 2. Disconnect the scan tool from the DLC. The following tests will be done at the DLC connector. 3. All access doors closed, ignition OFF for 60 seconds, test for less than 10 ohm between the ground circuit terminal 5 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 4. Ignition ON, test for less than 4.5 V between the serial data circuits listed below and ground: * Terminal 12 * Terminal 13 ‹› If greater than the specified range, test the serial data circuit for a short to voltage. Refer to Testing the Serial Data Circuits for a Short to Voltage. 5. Ignition OFF for 60 seconds, test for greater than 100 ohm between the serial data circuits listed below and ground: * Terminal 12 * Terminal 13 ‹› If not the specified value, test the serial data circuit for a short to ground. Refer to Testing the Serial Data Circuits for a Short to ground. 6. Test for 50-70 ohm between the serial data circuits terminal 12 and terminal 13. ‹› If less than 35 ohm, test for a short between the serial data circuits. Refer to Testing the Serial Data Circuits for a Short between the Circuits. ‹› If 35-50 ohm there may be a third terminating resistor between the serial data circuits. This can happen if the incorrect control module is installed. Some control modules are available with and without the terminating resistors installed to reduce the need of terminating resistors in the wiring harness. ‹› If greater than 70 ohm but less than infinite, test the serial data circuit for an open/high resistance. Refer to Testing the Serial Data Circuits for an Open/High Resistance. ‹› If infinite, test the serial data circuits between the DLC and the first connection to the serial data circuit for an open/high resistance. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2686 Testing the Serial Data Circuits for a Short to Voltage 1. Ignition OFF, disconnect the harness connectors with the chassis high speed GMLAN serial data circuits at an easily accessible control module. 2. Ignition ON, test for greater than 4.5 V between each serial data circuit at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are greater than 4.5 V. ‹› If all serial data circuits are less than the specified range, replace the control module that was disconnected. 3. Ignition OFF, disconnect the harness connectors with the chassis high speed GMLAN serial data circuits at another control module, in the direction of the circuit shorted to voltage. 4. Ignition ON, test for greater than 4.5 V between the serial data circuits at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are greater than 4.5 V. ‹› If all serial data circuits are less than the specified range, replace the control module that was just disconnected. 5. Repeat step 3 until one of the follow conditions are isolated: * A short to voltage on the serial data circuit between 2 control modules or splice packs, if equipped * A short to voltage on the serial data circuit between a control module and a terminating resistor. Testing the Serial Data Circuits for a Short to Ground 1. Ignition OFF, disconnect the harness connectors with the chassis high speed GMLAN serial data circuits at an easily accessible control module. 2. Ignition OFF for 60 seconds, test for less than 1k ohm between each serial data circuit at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are less than 1k ohm. ‹› If all serial data circuits are greater than the specified range, replace the control module that was disconnected. 3. Disconnect the harness connectors with the chassis high speed GMLAN serial data circuits at another control module, in the direction of the circuit shorted to ground. 4. Ignition OFF for 60 seconds, test for less than 1k ohm between the serial data circuits at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are less than 1k ohm. ‹› If greater than the specified range for all serial data circuits, replace the control module that was just disconnected. 5. Repeat step 3 until one of the follow conditions are isolated: * A short to ground on the serial data circuit between 2 control modules or splice packs, if equipped * A short to ground on the serial data circuit between a control module and a terminating resistor. Testing the Serial Data Circuits for a Short between the Circuits 1. Ignition OFF, disconnect the harness connectors with the chassis high speed GMLAN serial data circuits at an easily accessible control module that is not communicating. 2. Ignition OFF for 60 seconds, test for less than 35 ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are less than 35 ohm. ‹› If each pair of serial data circuits is greater than the specified range, replace the control module that was disconnected. 3. Connect the harness connectors at the control module that was disconnected. 4. Disconnect the harness connectors with the chassis high speed GMLAN serial data circuits at another control module, in the direction of the circuits shorted together. 5. Ignition OFF for 60 seconds, test for less than 35 ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are less than 35 ohm. ‹› If each pair of serial data circuits is within the specified range, replace the control module that was just disconnected. 6. Repeat step 3 until one of the following conditions are isolated: * Serial data circuits shorted together between 2 control modules or splice packs, if equipped * Serial data circuits shorted together between a control module and a terminating resistor * A shorted terminating resistor Testing the Serial Data Circuits for an Open/High Resistance 1. Ignition OFF, disconnect the harness connectors with the chassis high speed GMLAN serial data circuits at an easily accessible control module that is not communicating. 2. Ignition OFF for 60 seconds, test for greater than 100k ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are greater than 100k ohm. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2687 ‹› If each pair of serial data circuits is less than the specified range, replace the control module that was disconnected. 3. Connect the harness connectors at the control module that was disconnected. 4. Disconnect the harness connectors with the chassis high speed GMLAN serial data circuits at another control module, in the direction of the open circuit. 5. Ignition OFF for 60 seconds, test for greater than 100k ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are greater than 100k ohm. ‹› If each pair of serial data circuits is less than the specified range, replace the control module that was just disconnected. 6. Repeat step 3 until one of the following conditions are isolated: * An open/high resistance on the serial data circuit between 2 control modules or splice packs, if equipped * An open/high resistance on the serial data circuit between a control module and a terminating resistor * An open/high resistance terminating resistor Repair Instructions Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the repair. * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * Control Module References (See: Testing and Inspection/Programming and Relearning) for control module replacement, setup, and programming Scan Tool Does Not Communicate with High Speed GMLAN Device Scan Tool Does Not Communicate with High Speed GMLAN Device Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The serial data is transmitted on two twisted wires that allow speeds up to 500 Kb/s. The twisted pair is terminated with two 120 ohms resistors, one is internal to the engine control module (ECM) and the other can be a separate resistor in a connector assembly or in another control module. The resistors are used as the load for the High Speed GMLAN buss during normal vehicle operation. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level of approximately 2.5 V. Driving the lines to their extremes, adds one volt to the high speed GMLAN serial data bus (+) circuit and subtracts one volt from the high speed GMLAN serial data bus (-) circuit. If serial data is lost, control modules will set a no communication code against the non-communicating control module. Note that a loss of serial data DTC does not represent a failure of the module that set it. Diagnostic Aids Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2688 * Sometimes, while diagnosing a specific customer concern or after a repair, you may notice a history U-code present. However, there is no associated "current" or "active" status. Loss-of-communication U-codes such as these can set for a variety of reasons. Many times, they are transparent to the vehicle operator and technician, and/or have no associated symptoms. Eventually, they will erase themselves automatically after a number of fault-free ignition cycles. This condition would most likely be attributed to one of these scenarios: - A control module on the data communication circuit was disconnected while the communication circuit is awake. - Power to one or more modules was interrupted during diagnosis. - A low battery condition was present, so some control modules stop communicating when battery voltage drops below a certain threshold. - Battery power was restored to the vehicle and control modules on the communication circuit did not all re-initialize at the same time. - If a loss-of-communication U-code appears in history for no apparent reason, it is most likely associated with one of the scenarios above. These are all temporary conditions and should never be interpreted as an intermittent fault, causing you to replace a part. * Do not replace a control module reporting a U code. The U code identifies which control module needs to be diagnosed for a communication issue. * Communication may be available between the BCM and the scan tool with the high speed GMLAN serial data system inoperative. This condition is due to the BCM using both the high and low speed GMLAN systems. * An open in the DLC ground circuit terminal 5 will allow the scan tool to operate but not communicate with the vehicle. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. * Technicians may find various Local Area Network (LAN) communication Diagnostic Trouble Codes (DTC) and no low speed GMLAN communications with the scan tool. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. These conditions may be caused by the installation of an aftermarket navigation radio module (see bulletins). Some customers may comment of one or more of the following concerns: - Vehicle will not crank - Vehicle cranks but will not start - Vehicle stability enhancement system warning lights and messages - PRNDL gear indicator position errors Reference Information Schematic Reference * Data Communication Schematics (See: Diagrams/Electrical Diagrams) * Control Module References (See: Testing and Inspection/Programming and Relearning) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Description and Operation Data Link Communications Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Testing Note: Each control module may need to be disconnected to isolate a circuit fault. Use the schematic to identify the following: * Control modules the vehicle is equipped with * High speed GMLAN serial data circuit terminating resistors * Control module locations on the high speed GMLAN serial data circuits * Each control module's high speed GMLAN serial data circuit terminals Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2689 1. Attempt to communicate with all control modules on the high speed GMLAN serial data circuit Refer to Data Link References (See: Initial Inspection and Diagnostic Overview). Communications should not be available with two or more control modules on the high speed GMLAN serial data circuit. ‹› If only one control module is not communicating, diagnose that control module only. Refer to DTC U0100-U02FF (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts). 2. Disconnect the scan tool from the DLC. The following tests will be done at the DLC connector. 3. All access doors closed, ignition OFF for 60 seconds, test for less than 10 ohm between the ground circuit terminal 5 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 4. Ignition ON, test for less than 4.5 V between the serial data circuits listed below and ground: * Terminal 6 * Terminal 14 ‹› If greater than the specified range, test the serial data circuit for a short to voltage. Refer to Testing the Serial Data Circuits for a Short to Voltage. 5. Ignition OFF for 60 seconds, test for greater than 100 ohm between the serial data circuits listed below and ground: * Terminal 6 * Terminal 14 ‹› If not the specified value, test the serial data circuit for a short to ground. Refer to Testing the Serial Data Circuits for a Short to ground. 6. Test for 50-70 ohm between the serial data circuits terminal 6 and terminal 14. ‹› If less than 35 ohm, test for a short between the serial data circuits. Refer to Testing the Serial Data Circuits for a Short between the Circuits. ‹› If 35-50 ohm there may be a third terminating resistor between the serial data circuits. This can happen if the incorrect control module is installed. Some control modules are available with and without the terminating resistors installed to reduce the need of terminating resistors in the wiring harness. ‹› If greater than 70 ohm but less than infinite, test the serial data circuit for an open/high resistance. Refer to Testing the Serial Data Circuits for an Open/High Resistance. ‹› If infinite, test the serial data circuits between the DLC and the first connection to the serial data circuit for an open/high resistance. Testing the Serial Data Circuits for a Short to Voltage 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module. 2. Ignition ON, test for greater than 4.5 V between each serial data circuit at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are greater than 4.5 V. ‹› If all serial data circuits are less than the specified range, replace the control module that was disconnected. 3. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the circuit shorted to voltage. 4. Ignition ON, test for greater than 4.5 V between the serial data circuits at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are greater than 4.5 V. ‹› If all serial data circuits are less than the specified range, replace the control module that was just disconnected. 5. Repeat step 3 until one of the follow conditions are isolated: * A short to voltage on the serial data circuit between 2 control modules or splice packs, if equipped * A short to voltage on the serial data circuit between a control module and a terminating resistor. Testing the Serial Data Circuits for a Short to Ground 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module. 2. Ignition OFF for 60 seconds, test for less than 1k ohm between each serial data circuit at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are less than 1k ohm. ‹› If all serial data circuits are greater than the specified range, replace the control module that was disconnected. 3. Disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the circuit shorted to ground. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2690 4. Ignition OFF for 60 seconds, test for less than 1k ohm between the serial data circuits at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are less than 1k ohm. ‹› If greater than the specified range for all serial data circuits, replace the control module that was just disconnected. 5. Repeat step 3 until one of the follow conditions are isolated: * A short to ground on the serial data circuit between 2 control modules or splice packs, if equipped * A short to ground on the serial data circuit between a control module and a terminating resistor. Testing the Serial Data Circuits for a Short between the Circuits 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module that is not communicating. 2. Ignition OFF for 60 seconds, test for less than 35 ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are less than 35 ohm. ‹› If each pair of serial data circuits is greater than the specified range, replace the control module that was disconnected. 3. Connect the harness connectors at the control module that was disconnected. 4. Disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the circuits shorted together. 5. Ignition OFF for 60 seconds, test for less than 35 ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are less than 35 ohm. ‹› If each pair of serial data circuits is within the specified range, replace the control module that was just disconnected. 6. Repeat step 3 until one of the following conditions are isolated: * Serial data circuits shorted together between 2 control modules or splice packs, if equipped * Serial data circuits shorted together between a control module and a terminating resistor * A shorted terminating resistor Testing the Serial Data Circuits for an Open/High Resistance 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module that is not communicating. 2. Ignition OFF for 60 seconds, test for greater than 100k ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are greater than 100k ohm. ‹› If each pair of serial data circuits is less than the specified range, replace the control module that was disconnected. 3. Connect the harness connectors at the control module that was disconnected. 4. Disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the open circuit. 5. Ignition OFF for 60 seconds, test for greater than 100k ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are greater than 100k ohm. ‹› If each pair of serial data circuits is less than the specified range, replace the control module that was just disconnected. 6. Repeat step 3 until one of the following conditions are isolated: * An open/high resistance on the serial data circuit between 2 control modules or splice packs, if equipped * An open/high resistance on the serial data circuit between a control module and a terminating resistor * An open/high resistance terminating resistor Repair Instructions Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the repair. * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * Control Module References (See: Testing and Inspection/Programming and Relearning) for control module replacement, setup, and programming Scan Tool Does Not Communicate with Low Speed GMLAN Device Scan Tool Does Not Communicate with Low Speed GMLAN Device Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2691 Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The serial data is transmitted over a single wire to the appropriate control modules. The transmission speed for GMLAN low speed is up to 83.33 Kb/s. Under normal vehicle operating conditions, the speed of the buss is 33.33 Kb/s. The control modules toggle the serial data circuit between 0-5 V during normal communications. To wake the control modules connected to the GMLAN low speed serial data circuit, a voltage wake up pulse of 10 V is sent out. If serial data is lost, control modules will set a no communication code against the non-communicating control module. A loss of serial data communications DTC does not represent a failure of the module that set it. Diagnostic Aids * Sometimes, while diagnosing a specific customer concern or after a repair, you may notice a history U-code present. However, there is no associated "current" or "active" status. Loss-ofcommunication U-codes such as these can set for a variety of reasons. Many times, they are transparent to the vehicle operator and technician, and/or have no associated symptoms. Eventually, they will erase themselves automatically after a number of fault-free ignition cycles. This condition would most likely be attributed to one of these scenarios: - A control module on the data communication circuit was disconnected while the communication circuit is awake. - Power to one or more modules was interrupted during diagnosis - A low battery condition was present, so some control modules stop communicating when battery voltage drops below a certain threshold. - Battery power was restored to the vehicle and control modules on the communication circuit did not all re-initialize at the same time. - If a loss-of-communication U-code appears in history for no apparent reason, it is most likely associated with one of the scenarios above. These are all temporary conditions and should never be interpreted as an intermittent fault, causing you to replace a part. * Do not replace a control module reporting a U-code. The U-code identifies which control module needs to be diagnosed for a communication issue. * Communication may be available between the body control module (BCM) and the scan tool with the low speed GMLAN serial data system inoperative. This condition is due to the BCM using both the high and low speed GMLAN systems. * An open in the low speed GMLAN serial data circuit between the splice pack and a module will only affect that specific module. This type of failure will set a loss of communication DTC for each module effected, and the other modules will still communicate. * An open in the data link connector (DLC) ground circuit terminal 5 will allow the scan tool to operate but not communicate with the vehicle. * The engine may not start when there is a total malfunction of the low speed GMLAN serial data circuit. * Technicians may find various Local Area Network (LAN) communication Diagnostic Trouble Codes (DTC) and no low speed LAN communications with the scan tool. These conditions may be caused by the installation of an aftermarket navigation radio module (see bulletins). Some customers may comment of one or more of the following concerns: - Vehicle will not crank - Vehicle cranks but will not start - Vehicle stability enhancement system warning lights and messages - PRNDL gear indicator position errors Reference Information Schematic Reference Data Communication Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2692 Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Description and Operation Data Link Communications Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Circuit/System Testing Note: Use the schematic to identify the following: * Control modules the vehicle is equipped with * Control module and splice pack locations on the low speed GMLAN serial data circuit * The low speed GMLAN serial data circuit terminals for each control module, component, or splice pack 1. Attempt to communicate with all control modules on the low speed GMLAN serial data circuit. Refer to Data Link References (See: Initial Inspection and Diagnostic Overview). Communications should not be available with two or more control modules on the low speed GMLAN serial data circuit. ‹› If only one control module is not communicating, diagnose that control module only. Refer to DTC U0100-U02FF. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts ‹› If one or more control modules are communicating but not all, refer to Testing the Serial Data Circuit for an Open/High Resistance. 2. Disconnect the scan tool from the DLC. The following tests will be done at the DLC connector. 3. All access doors closed, ignition OFF for 60 seconds, test for less than 10 ohm between the ground circuit terminal 5 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 4. Ignition ON, test for less than 4.5 V between the serial data circuit terminal 1 and ground. ‹› If greater than the specified range, test the serial data circuit for a short to voltage. Refer to Testing the Serial Data Circuit for a Short to Voltage. 5. Ignition OFF for 60 seconds, test for greater than 100 ohm between the serial data circuit terminal 1 and ground. ‹› If less than the specified range, test the serial data circuit for a short to ground. Refer to Testing the Serial Data Circuits for a Short to ground. 6. Disconnect the harness connector at the first splice pack closest in the circuit to the DLC. 7. Test for less than 2 ohm between the DLC serial data circuit terminal 1 and the splice pack connector serial data input terminal. ‹› If greater than the specified range, test the serial data circuit for an open/high resistance. If the circuit tests normal, replace the splice pack. Testing the Serial Data Circuits for a Short to Voltage 1. Ignition OFF, disconnect the appropriate harness connectors at the following components: * All low speed serial data splice packs * Any module or component between that may be between the splice packs 2. Ignition ON, test for less than 4.5 V between the DLC serial data circuit terminal 1 and ground. ‹› If greater than the specified range, repair the short to voltage. 3. Test for less than 4.5 V between each serial data circuit at each component connector and ground. ‹› If greater than the specified range, perform the appropriate test listed below: * Serial data circuits with one control module, test the serial data circuit for a short to voltage. If the circuit tests normal, replace the control Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2693 module. * Serial data circuits with 2 or more control modules, test each section of the serial data circuit for a short to voltage. If the circuits test normal, replace the control module that causes the short to voltage when connected. Testing the Serial Data Circuits for a Short to Ground 1. Ignition OFF, disconnect the appropriate harness connectors at the following components: * All low speed serial data splice packs * Any module or component between that may be between the splice packs 2. Test for infinite resistance between the DLC serial data circuit terminal 1 and ground. ‹› If not the specified value, repair the short to ground. 3. Ignition OFF for 60 seconds, test for greater than 100 ohm between each serial data circuit at the splice pack and ground. ‹› If less than the specified range, perform the appropriate test listed below: * Serial data circuits with one control module, test the serial data circuit for a short to ground. If the circuit tests normal, replace the control module. * Serial data circuits with 2 or more control modules, test each section of the serial data circuit for a short to ground. If the circuits test normal, replace the control module that causes the short to ground when connected. Testing the Serial Data Circuit for an Open/High Resistance 1. If equipped with a second splice pack, ignition ON, verify the scan tool communicates with one or more control modules connected to the second splice pack. ‹› If all control modules on the second splice pack do not communicate, test the serial data circuit between the first and second splice packs for an open/high resistance. If the circuit tests normal, test the second splice pack for an open/high resistance. If the splice pack tests normal, replace any module or component that may be between those two splice packs. 2. If equipped with a third splice pack, ignition ON, verify the scan tool communicates with one or more control modules connected to the third splice pack. ‹› If all control modules on the third splice pack do not communicate, test the serial data circuit between the second and third splice packs for an open/high resistance. If the circuit tests normal, test the third splice pack for an open/high resistance. If the splice pack tests normal, replace any module or component that may be between the those two splice packs. 3. Ignition OFF, disconnect the splice pack containing the serial data circuits to the modules that are not communicating. 4. Install a 3 A fused jumper wire between the splice pack connector serial data input terminal and a low speed GMLAN serial data circuit that is not communicating: 5. Ignition ON, verify the scan tool communicates with the control modules connected to the low speed GMLAN serial data circuit. ‹› If any control module does not communicate, test each section of the serial data circuit for an open/high resistance. If the circuits test normal, replace the control module that does not communicate when connected. Repair Instructions Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * Control Module References (See: Testing and Inspection/Programming and Relearning) for module replacement, programming and setup Scan Tool Does Not Power Up Scan Tool Does Not Power Up Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2694 * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: * Scan tool B+ voltage at terminal 16 * Scan tool ground at terminal 4 * Common ground at terminal 5 Diagnostic Aids * The scan tool will power up with the ignition OFF. Some modules however, will not communicate unless the ignition is ON and the power mode master module sends the appropriate power mode message. * If the B+ circuit, ground circuits, and connections of the DLC are functioning properly, the malfunction must be due to the scan tool. Reference Information Schematic Reference Data Communication Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Description and Operation Data Link Communications Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information. Circuit/System Testing 1. Test for less than 2.0 ohm between the ground circuits terminal 4 of the DLC and ground, and terminal 5 of the DLC and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 2. Ignition ON, verify a test lamp illuminates between the B+ circuit terminal 16 at the DLC and ground. ‹› If the test lamp does not illuminate, test the voltage supply circuit for a short to ground or an open/high resistance. 3. If all circuits test normal, refer to the scan tool user guide. Repair Instructions Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2695 Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the repair. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views Knock Sensor: Locations Disassembled Views Disassembled Views Engine Block Assembly - 1.4L LDD 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Engine Block 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views > Page 2700 16 - Oil Pan Bolt 17 - Oil Pan Drain Plug Seal Ring 18 - Oil Pan Drain Plug 19 - Crankshaft Position Sensor Bolt 20 - Crankshaft Position Sensor 21 - Crankshaft Position Sensor Seal Ring 22 Crankshaft Bearing Cap Tie Plate Bolt (M8) 23 - Crankshaft Position Sensor Reluctor Ring 24 Flywheel Bolt 25 - Engine Flywheel 26 - Crankshaft Rear Oil Seal 27 - Crankshaft Position Sensor Reluctor Ring Bolt 28 - Connecting Rod Bearing Cap Bolt 29 - Connecting Rod Bearing Cap 30 Lower Connecting Rod Bearing 31 - Upper Connecting Rod Bearing 32 - Connecting Rod 33 Piston Pin 34 - Piston 35 - Piston Oil Ring (With oil Ring Spacer) 36 - Lower Compression Ring 37 - Upper Compression Ring Engine Block Assembly - 1.4L LUH and LUJ Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views > Page 2701 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Cylinder Head 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Baffle 16 - Oil Pan Baffle Bolt 17 - Oil Pan 18 - Oil Pan Bolt 19 - Oil Pan Drain Plug 20 - Crankshaft Position Sensor Bolt 21 - Crankshaft Position Sensor 22 - Crankshaft Position Sensor Seal Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views > Page 2702 23 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 24 - Piston Oil Nozzle 25 - Crankshaft Position Sensor Reluctor Ring 26 - Crankshaft Position Sensor Reluctor Ring Bolt 27 - Crankshaft Rear Oil Seal 28 - Engine Flywheel (Two-Mass) 29 - Engine Flywheel Bolt 30 - Connecting Rod Bearing Cap Bolt 31 - Connecting Rod Bearing Cap 32 - Lower Connecting Rod Bearing 33 - Upper Connecting Rod Bearing 34 - Connecting Rod 35 - Piston Pin 36 - Piston Pin Retainer 37 - Piston Pin Retainer 38 - Piston 39 - Piston Oil Ring (With Oil Ring Spacer) 40 - Lower Compression Ring 41 - Upper Compression Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views > Page 2703 Knock Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Left Rear (LUJ) 1 - B111 Turbocharger Boost Pressure Sensor 2 - T8 Ignition Coil 3 - B68 Knock Sensor (KS) 4 Q38 Throttle Body 5 - B34 Engine Coolant Temperature Sensor Lower Rear of the Engine Components 1 of 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views > Page 2704 1 - B68 Knock Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2705 Knock Sensor: Description and Operation Knock Sensor System Description Circuit/System Description The knock sensor system enables the engine control module (ECM) to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The ECM uses the knock sensor system to test for abnormal engine noise that may indicate detonation, also known as spark knock. Sensor Description This knock sensor system uses one or two flat response dual-wire sensors. The sensor uses piezo-electric crystal technology that produces an alternating current (AC) voltage signal of varying amplitude and frequency based on the engine vibration or noise level. The amplitude and frequency are dependant upon the level of knock that the knock sensor detects. The ECM receives the knock sensor signal through 2 isolated signal circuits. If the ECM has determined that knock is present, it will retard the ignition timing to attempt to reduce the knock. The ECM is capable of controlling spark retard on an individual cylinder basis. The ECM will always try to work back to a zero compensation level, or no spark retard. knock sensor diagnostics are calibrated to detect faults with the knock sensor circuitry inside the ECM, the knock sensor wiring, or the knock sensor voltage output. Some diagnostics are also calibrated to detect constant noise from an outside influence such as a loose/damaged component or excessive mechanical engine noise. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2706 Knock Sensor: Service and Repair Knock Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood Main Relay (Computer/Fuel System): Locations Fuse Block - Underhood Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 2711 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 2712 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 2713 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 2714 Main Relay (Computer/Fuel System): Locations Fuse Block - Instrument Panel Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 2715 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module (ECM) turns the MIL ON by grounding the MIL control circuit. Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) DTC Type Reference Powertrain Diagnostic Trouble Code (DTC) Type Definitions (See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Powertrain Diagnostic Trouble Code (DTC) Type Definitions) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Circuit/System Verification 1. Ignition ON, observe the DTC information with a scan tool. Verify that DTCs U0073 00, U0100 00, or U0155 00 are not set. ‹› If any of the DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle). 2. Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool. Circuit/System Testing Ignition ON, verify that the P16 Instrument Cluster warning indicators are illuminated. If the P16 Instrument Cluster warning indicators are not illuminated, test the P16 Instrument Cluster ignition circuit terminal 31 for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the P16 Instrument Cluster. Repair Instructions Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Page 2719 * Instrument Cluster Replacement (See: Instrument Panel, Gauges and Warning Indicators/Compass/Service and Repair) * Control Module References (See: Testing and Inspection/Programming and Relearning)for ECM replacement, setup, and programming Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Disassembled Views Manifold Pressure/Vacuum Sensor: Locations Disassembled Views Disassembled Views Intake Manifold Assembly - 1.4L LUH and LUJ 1 - Fuel Injector Fuel Rail 2 - Fuel Injector Fuel Rail Bolt 3 - Manifold Absolute Pressure Sensor 4 Manifold Absolute Pressure Sensor Bolt 5 - Evaporative Emission Canister Purge Solenoid Valve 6 - Intake Manifold 7 - Throttle Body Seal Ring 8 - Throttle Body 9 - Throttle Body Bolt 10 - Intake Manifold Gasket Intake Manifold Assembly - 1.4L LDD Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Disassembled Views > Page 2724 1 - Intake Manifold Sealings 2 - Intake Manifold (With Intake Manifold Runner and Intake Manifold Runner Valve) 3 - Throttle Body Bolt 4 - Throttle Body 5 - Throttle Body Seal Ring 6 - Fuel Injection Fuel Rail Bolt 7 - Evaporative Emission Canister Purge Solenoid Valve 8 - Evaporative Emission Canister Purge Solenoid Valve Rubber 9 - Evaporative Emission Canister Purge Solenoid Valve Bracket Bolt 10 - Evaporative Emission Canister Purge Solenoid Valve Bracket 11 - Fuel Injection Fuel Rail 12 - Fuel Injector Retainer Clamp 13 - Fuel Injector 14 - Manifold Absolute Pressure Sensor Bolt 15 - Manifold Absolute Pressure Sensor 16 - Manifold Absolute Pressure Sensor Seal Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Disassembled Views > Page 2725 Manifold Pressure/Vacuum Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Rear (LUJ) 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2726 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Disassembled Views Oxygen Sensor: Locations Disassembled Views Disassembled Views Exhaust Side - 1.4L LUH and LUJ 1 - Positive Crankcase Ventilation Pipe Assembly 2 - Exhaust Manifold Gasket 3 - Turbo Charger Oil Feed Pipe Hollow Screw 4 - Turbo Charger Oil Feed Pipe 5 - Turbo Charger Oil Feed Pipe Bolt 6 - Oil Cooler Coolant Outlet Hose 7 - Oil Cooler Coolant Outlet Hose Clamp 8 - Oil Cooler Coolant Feed Pipe Bolt 9 - Oil Cooler Coolant Feed Pipe 10 - Engine Oil Cooler Assembly 11 - Catalytic Converter Bracket 12 - Catalytic Converter to Catalytic Converter Bracket Nut 13 - Turbocharger Coolant Return Pipe 14 - Turbocharger Coolant Feed Pipe Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Disassembled Views > Page 2731 15 - Turbocharger Coolant Feed Pipe Hollow Screw 16 - Heated Oxygen Sensor 1 17 - Catalytic Converter 18 - Catalytic Converter Heat Shield 19 - Catalytic Converter Heat Shield Bolt 20 Catalytic Converter Seal 21 - Catalytic Converter V-Clamp 22 - Turbocharger Oil Return Pipe 23 Turbocharger Oil Return Pipe Bolt 24 - Exhaust Manifold Heat Shield 25 - Exhaust Manifold Heat Shield Bolt 26 - Turbocharger (with Exhaust Manifold) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Disassembled Views > Page 2732 Oxygen Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Front (LUJ) 1 - Q6E Camshaft Position Actuator Solenoid Valve - Exhaust 2 - B23E Camshaft Position Sensor Exhaust 3 - B37 Engine Oil Pressure Switch 4 - B52A Heated Oxygen Sensor 1 5 - Q42 Turbocharger Wastegate Solenoid Valve 6 - Q2 A/C Compressor Clutch Engine Components - Right Rear (LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Disassembled Views > Page 2733 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Caution > Page 2736 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Caution > Page 2737 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Sensor 1 Heated Oxygen Sensor Replacement - Sensor 1 (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Sensor 1 > Page 2740 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Sensor 2 Heated Oxygen Sensor Replacement - Sensor 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Recalls for Body Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Body Control Module: Recalls Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Recalls for Body Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 2750 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Recalls for Body Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 2751 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Body Control Module: All Technical Service Bulletins Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 2757 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 2758 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2759 Body Control Module: Locations Instrument Panel/Center Console Component Views Behind the Center of the I/P Components 1 of 4 1 - K9 Body Control Module 2 - X7 Body Control Module X7 3 - X6 Body Control Module X6 4 - X5 Body Control Module X5 5 - X4 Body Control Module X4 6 - X3 Body Control Module X3 7 - X2 Body Control Module X2 8 - X1 Body Control Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2760 Body Control Module: Diagrams Component Connector End Views K9 Body Control Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2761 K9 Body Control Module X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2762 K9 Body Control Module X3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2763 K9 Body Control Module X4 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2764 K9 Body Control Module X5 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2765 K9 Body Control Module X6 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2766 K9 Body Control Module X7 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2767 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Body Control Module Replacement Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Body Control Module Replacement > Page 2770 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues Engine Control Module: Recalls Campaign - Thermostat Sticks Open Causes Shift Issues SERVICE UPDATE Bulletin No.: 10399A Date: December 02, 2010 Subject: 10399A - Service Update for Inventory and Customer Vehicles - Powertrain Improvements - Thermostat Sticks in Open Position and Shift Quality - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with a 1.4L Turbo Engine (LUJ) Supercede: The Subject and Purpose in this bulletin are being revised to advise that the new ECM calibration will also address shift quality issues.Please discard all copies of bulletin 10399, issued November 2010. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to reprogram the engine control module (ECM) on certain 2011 model year Chevrolet Cruze vehicles equipped with a 1.4L turbo engine (LUJ). These vehicles may have a condition where the thermostat sticks in the open position. If this occurs, diagnostic codes will be set and the Service Vehicle Soon light/message will illuminate. These vehicles may also have transmission shift quality issues due to calibration values. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. Additionally, a list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should also be checked for vehicle eligibility. Parts Information No parts are required for this update. Service Procedure Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 11/29/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming. 2. Reprogram the engine control module (ECM) and transmission control module (TCM) in sequence. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI or Tech 2(R) to the vehicle. If using MDI, connect to programming terminal with the cable (USB or LAN). 2. Select J-2534 MDI or J-2534 Tech 2(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues > Page 2779 3. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. 4. Follow the on-screen instructions. 3. Clear all DTCs using the GDS or Tech 2(R). Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Engine Control Module: Recalls Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 2784 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 2785 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues Engine Control Module: All Technical Service Bulletins Campaign - Thermostat Sticks Open Causes Shift Issues SERVICE UPDATE Bulletin No.: 10399A Date: December 02, 2010 Subject: 10399A - Service Update for Inventory and Customer Vehicles - Powertrain Improvements - Thermostat Sticks in Open Position and Shift Quality - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with a 1.4L Turbo Engine (LUJ) Supercede: The Subject and Purpose in this bulletin are being revised to advise that the new ECM calibration will also address shift quality issues.Please discard all copies of bulletin 10399, issued November 2010. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to reprogram the engine control module (ECM) on certain 2011 model year Chevrolet Cruze vehicles equipped with a 1.4L turbo engine (LUJ). These vehicles may have a condition where the thermostat sticks in the open position. If this occurs, diagnostic codes will be set and the Service Vehicle Soon light/message will illuminate. These vehicles may also have transmission shift quality issues due to calibration values. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. Additionally, a list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should also be checked for vehicle eligibility. Parts Information No parts are required for this update. Service Procedure Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 11/29/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming. 2. Reprogram the engine control module (ECM) and transmission control module (TCM) in sequence. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI or Tech 2(R) to the vehicle. If using MDI, connect to programming terminal with the cable (USB or LAN). 2. Select J-2534 MDI or J-2534 Tech 2(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues > Page 2791 3. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. 4. Follow the on-screen instructions. 3. Clear all DTCs using the GDS or Tech 2(R). Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 2796 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Engine Control Module: All Technical Service Bulletins Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 2801 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 2802 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 2807 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 2808 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 2809 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 2815 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 2820 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 2821 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-06-04-026C > Aug > 10 > Engine/Transmission - Aftermarket Calibrations > Page 2822 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2823 Engine Control Module: Description and Operation Engine Control Module Description The engine control module (ECM) interacts with many emission related components and systems, and monitors the emission related components and systems for deterioration. OBD II diagnostics monitor the system performance and a diagnostic trouble code (DTC) sets if the system performance degrades. The malfunction indicator lamp (MIL) operation and the DTC storage are dictated by the DTC type. A DTC is ranked as a type A or type B if the DTC is emissions related. Type C is a non emissions related DTC. The ECM is located in the engine compartment. The ECM is the control center of the engine controls system. The ECM controls the following components: * The fuel injection system * The ignition system * The emission control systems * The on-board diagnostics * The A/C and fan systems * The throttle body motor system The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect the vehicle performance and the emissions. The ECM also performs diagnostic tests on various parts of the system. The ECM can recognize operational conditions and alert the driver via the MIL. When the ECM detects a malfunction, the ECM stores a DTC. The condition area is identified by the particular DTC that is set. This helps the technician in making repairs. ECM Function The engine control module (ECM) can supply 5 V or 12 V to the various sensors or switches. This is done through pull-up resistors to the regulated power supplies within the ECM. In some cases, even an ordinary shop voltmeter will not give an accurate reading because the resistance is too low. Therefore, a DMM with at least 10 Mohm input impedance is required in order to ensure accurate voltage readings. The ECM controls the output circuits by controlling the ground or the power feed circuit through the transistors or a device called an output driver module. EEPROM The programmable read only memory (EEPROM), which can be erased electronically, is a permanent memory that is physically part of the engine control module (ECM). The EEPROM contains program and calibration information that the ECM needs in order to control the powertrain operation. Special equipment, as well as the correct program and calibration for the vehicle, are required in order to reprogram the ECM. ECM Default Actions When a malfunction occurs within the engine control system, the engine control module (ECM) maintains control of the system with default actions. Default actions are calculated values, and/or calibrated default values, that are stored within the ECM. A certain level of engine performance is possible when a malfunction occurs dependant on the default actions taken. The ECM default actions prevent a complete loss of engine performance. ECM Output Controls The scan tool can control certain solenoids, valves, motors, and relays. The output controls can be found under the special functions selection of the scan tool. Some output controls may be disabled by the engine control module (ECM) during certain types of vehicle operation. Data Link Connector (DLC) The data link connector (DLC) is a 16-pin connector that provides the technician with a means of accessing serial data for aid in the diagnosis. This connector allows the technician to use a scan tool in order to monitor the various serial data parameters, and display the DTC information. The DLC is located inside the drivers compartment, underneath the dash. Malfunction Indicator Lamp (MIL) The malfunction indicator lamp (MIL) is located on the instrument panel cluster, or the driver information center. The MIL is controlled by the engine control module (ECM) and illuminates when the ECM detects a condition that affects the vehicle emissions. ECM Service Precautions Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2824 The engine control module (ECM), by design, can withstand the normal current draws that are associated with the vehicle operations. However, care must be taken in order to avoid overloading any of these circuits. When testing for opens or shorts, do not ground or apply voltage to any of the ECM circuits unless the diagnostic procedure instructs you to do so. These circuits should only be tested with a DMM. Aftermarket (Add-On) Electrical And Vacuum Equipment Caution: Do not attach add-on vacuum operated equipment to this vehicle. The use of add-on vacuum equipment may result in damage to vehicle components or systems. Caution: Connect any add-on electrically operated equipment to the vehicle's electrical system at the battery (power and ground) in order to prevent damage to the vehicle. Aftermarket, add-on, electrical and vacuum equipment is defined as any equipment installed on a vehicle after leaving the factory that connects to the vehicles electrical or vacuum systems. No allowances have been made in the vehicle design for this type of equipment. Add-on electrical equipment, even when installed to these strict guidelines, may still cause the powertrain system to malfunction. This may also include equipment not connected to the vehicle electrical system, such as portable telephones and radios. Therefore, the first step in diagnosing any powertrain condition is to make sure all of the after-market electrical equipment is removed or disconnected from the vehicle. After this has been done and if the condition still exists, the condition may be diagnosed in the normal manner. Electrostatic Discharge (ESD) Damage Note: In order to prevent possible electrostatic discharge damage to the ECM, do not touch the connector pins on the ECM. The electronic components that are used in the control systems are often designed to carry very low voltage. The electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 V of static electricity can cause damage to some electronic components. By comparison, it takes as much as 4 000 V for a person to even feel the zap of a static discharge. There are several ways for a person to become statically charged. The most common methods of charging are by friction and by induction. An example of charging by friction is a person sliding across a car seat. Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground. Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage, therefore, it is important to exercise great care when handling and testing electronic components. Emission Control Information Label The underhood vehicle emissions control information label contains important emission specifications and setting procedures. This identifies the year, the manufacturing division of the engine, the displacement of the engine in liters, the class of the vehicle, and type of fuel metering system. There is also an illustrated emission components and vacuum hose schematic. This label is located in the engine compartment of every General Motors vehicle. If the label has been removed, it can be ordered from GM service parts operations (GMSPO). Underhood Inspection Note: This inspection is very important and must be done carefully and thoroughly. Perform a careful underhood inspection when performing any diagnostic procedure or diagnosing the cause of an emission test failure. This can often lead to repairing a condition without further steps. Use the following guidelines when performing an inspection: * Inspect all of the vacuum hoses for correct routing, pinches, cuts, or disconnects. * Inspect any hoses that are difficult to see. * Inspect all of the wires in the engine compartment for the following conditions: - Burned or chafed spots - Pinched wires - Contact with sharp edges - Contact with hot exhaust manifolds Basic Knowledge Required Caution: Lack of basic knowledge of this powertrain when performing diagnostic procedures could result in incorrect diagnostic performance or damage to powertrain components. Do not attempt to diagnose a powertrain problem without this basic knowledge. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2825 A basic understanding of hand tools is necessary in order to effectively use this section of the service manual. You must be familiar with some of the basics of engine operation and electrical diagnosis in order to use this section of the service manual. * Basic electrical circuits, You should have an understanding of basic electricity and know the meaning of voltage (V), current (A), and resistance (ohm). You should understand what happens in a circuit with an open or a shorted wire, and you should be able to identify a shorted or open circuit by using a digital multimeter (DMM). You should be able to read and understand a wiring diagram. * Use of digital multimeter, You should be familiar with the DMM, particularly the essential tool. You should be able to use the meter in order to measure the voltage (V), the resistance (ohm), the current (A), intermittent (minimum/maximum), and frequency (Hz). * Use of circuit testing tools, You should not use a test lamp to diagnose the engine controls system unless you are specifically instructed to do so. You should know how to use jumper wires in order to test the components and allow DMM readings without damaging the terminals. You should know how to use the J 35616 - Adapter Kit and use the kit whenever the diagnostic procedures call for front probing any connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2826 Engine Control Module: Service and Repair Engine Control Module Replacement Removal Procedure Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note: It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last engine oil change. 1. Prepare the engine control module for the replacement. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). 2. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 3. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 4. Disconnect the 2 wiring harness plug (2) from the engine control module (3). 5. Unclip the engine control module bracket (4) from the battery tray. 6. Remove the 4 nuts (1). 7. Remove the engine control module (3) from the engine control module bracket (4). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2827 1. Install the engine control module (3) to the engine control module bracket (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 4 nuts (1) and tighten to 9 Nm (80 lb in). 3. Clip the engine control module bracket (4) to the battery tray. 4. Connect the 2 wiring harness plug (2) to the engine control module (3). 5. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 6. Program the ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood Main Relay (Computer/Fuel System): Locations Fuse Block - Underhood Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 2832 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 2833 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 2834 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 2835 Main Relay (Computer/Fuel System): Locations Fuse Block - Instrument Panel Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 2836 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2841 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views B107 Accelerator Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2842 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Right Front of the Vehicle Components 1 of 2 1 - B75B Mass Air Flow/Intake Air Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2846 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor Replacement (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations Barometric Pressure Sensor: Locations Powertrain Component Views Engine Components - Right Rear (LUJ) 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Current Sensor > Component Information > Locations Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Side of the Engine Compartment Components 2 of 2 1 - B18 Battery Current Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Current Sensor > Component Information > Locations > Page 2853 Battery Current Sensor: Diagrams Component Connector End Views B18 Battery Current Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Current Sensor > Component Information > Locations > Page 2854 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Open the hood. 2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Remove the battery ground cable nut (1). 4. Remove the battery negative cable (2). 5. Disconnect the wiring harness current sensor plug (4). 6. Remove the current sensor (5) from the battery tray. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Current Sensor > Component Information > Locations > Page 2855 7. Remove the current sensor (2) from the battery negative cable (1). Installation Procedure 1. Install the current sensor (2) to the battery negative cable (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Current Sensor > Component Information > Locations > Page 2856 2. Install the current sensor (5) to the battery tray. 3. Connect the wiring harness current sensor plug (4). 4. Install the battery negative cable (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the battery ground cable nut (1) and tighten to 9 Nm (80 lb in). 6. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 7. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle Camshaft Position Sensor: All Technical Service Bulletins Engine - Lack of Power with Multiple DTCs or Rattle TECHNICAL Bulletin No.: 10-06-04-016 Date: December 20, 2010 Subject: Engine Lack of Power with DTCs P0011, P0014, P000A, P000B, P0012, P0015 or Engine Rattle Noise (Remove Oil Filters from Intake and Exhaust Camshaft Position Actuator Solenoid Valves) Models: 2008-2011 Chevrolet Aveo 2011 Chevrolet Cruze (US and Canada) 2009-2011 Chevrolet Cruze (Export Only) 2008-2009 Pontiac G3, Wave 2008-2009 Saturn Astra Condition Some customers may comment on lack of power with the following DTCs or an engine rattle noise from the sprockets. Cruze GEN3 1.6/1.8D - P0011: Intake Camshaft Position (CMP) System Performance - P0014: Exhaust Camshaft Position (CMP) System Performance - P000A: Intake Camshaft Position System Slow Response - P000B: Exhaust Camshaft Position System Slow Response Aveo GEN3 1.4D - P0012: Intake Camshaft Position (CMP) System Performance Bank 1-Retarded - P0015: Exhaust Camshaft Position (CMP) System Performance Bank 1-Retarded Aveo/G3/Wave Gen3 1.6D - P0011: Intake Camshaft Position (CMP) System Performance Bank 1 - P0014: Exhaust Camshaft Position (CMP) System Performance Bank 1 Correction Remove four oil filters from the intake and exhaust camshaft position actuator solenoid valves. 1. Open the hood. 2. Disconnect the negative battery cable. 3. Disconnect the camshaft position actuator solenoid valve connectors. 4. Remove the power steering line bracket bolt and reposition the bracket (for 1.6/1.8L only). 5. Disconnect PCV pipe and reposition (for 1.6/1.8L only). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 2865 6. Remove the camshaft position actuator solenoid valve bolts. 7. Remove the camshaft position actuator solenoid valves and seals. 8. Check whether the filter is broken or not (1). 9. Remove the four filters (intake and exhaust). 1. Broken Filter: Remove filter with a blunt tool. 2. Unbroken Filter 1. Locate the filter hinge between the holes. 2. Cut the filter hinge slightly. Caution Do not scratch the valve surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 2866 3. Remove the filter with a blunt tool. 10. Install the camshaft position actuator solenoid valves and seals. Coat the seal with clean engine oil prior to installation. 11. Install the camshaft position actuator solenoid valve bolts. Tighten Tighten the bolts to 6 Nm (53 lb in). 12. Connect the camshaft position actuator solenoid valve connectors. 13. Reposition and install the PCV pipe (for 1.6/1.8 only). 14. Reposition the power steering bracket and install the power steering line bracket bolt (for 1.6/1.8 only). 15. Connect the negative battery cable. Note If an engine rattle noise is heard after removing the filters, refer to SI for further diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle Camshaft Position Sensor: Customer Interest Engine - Lack of Power with Multiple DTCs or Rattle TECHNICAL Bulletin No.: 10-06-04-016 Date: December 20, 2010 Subject: Engine Lack of Power with DTCs P0011, P0014, P000A, P000B, P0012, P0015 or Engine Rattle Noise (Remove Oil Filters from Intake and Exhaust Camshaft Position Actuator Solenoid Valves) Models: 2008-2011 Chevrolet Aveo 2011 Chevrolet Cruze (US and Canada) 2009-2011 Chevrolet Cruze (Export Only) 2008-2009 Pontiac G3, Wave 2008-2009 Saturn Astra Condition Some customers may comment on lack of power with the following DTCs or an engine rattle noise from the sprockets. Cruze GEN3 1.6/1.8D - P0011: Intake Camshaft Position (CMP) System Performance - P0014: Exhaust Camshaft Position (CMP) System Performance - P000A: Intake Camshaft Position System Slow Response - P000B: Exhaust Camshaft Position System Slow Response Aveo GEN3 1.4D - P0012: Intake Camshaft Position (CMP) System Performance Bank 1-Retarded - P0015: Exhaust Camshaft Position (CMP) System Performance Bank 1-Retarded Aveo/G3/Wave Gen3 1.6D - P0011: Intake Camshaft Position (CMP) System Performance Bank 1 - P0014: Exhaust Camshaft Position (CMP) System Performance Bank 1 Correction Remove four oil filters from the intake and exhaust camshaft position actuator solenoid valves. 1. Open the hood. 2. Disconnect the negative battery cable. 3. Disconnect the camshaft position actuator solenoid valve connectors. 4. Remove the power steering line bracket bolt and reposition the bracket (for 1.6/1.8L only). 5. Disconnect PCV pipe and reposition (for 1.6/1.8L only). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 2872 6. Remove the camshaft position actuator solenoid valve bolts. 7. Remove the camshaft position actuator solenoid valves and seals. 8. Check whether the filter is broken or not (1). 9. Remove the four filters (intake and exhaust). 1. Broken Filter: Remove filter with a blunt tool. 2. Unbroken Filter 1. Locate the filter hinge between the holes. 2. Cut the filter hinge slightly. Caution Do not scratch the valve surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 2873 3. Remove the filter with a blunt tool. 10. Install the camshaft position actuator solenoid valves and seals. Coat the seal with clean engine oil prior to installation. 11. Install the camshaft position actuator solenoid valve bolts. Tighten Tighten the bolts to 6 Nm (53 lb in). 12. Connect the camshaft position actuator solenoid valve connectors. 13. Reposition and install the PCV pipe (for 1.6/1.8 only). 14. Reposition the power steering bracket and install the power steering line bracket bolt (for 1.6/1.8 only). 15. Connect the negative battery cable. Note If an engine rattle noise is heard after removing the filters, refer to SI for further diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Disassembled Views Camshaft Position Sensor: Locations Disassembled Views Disassembled Views Engine Front Cover And Oil Pump Assembly (1 of 2) 1 - Camshaft Position Actuator Solenoid Valve Bolt 2 - Intake Camshaft Position Actuator Solenoid Valve 3 - Exhaust Camshaft Position Actuator Solenoid Valve 4 - Intake Camshaft Position Sensor Bolt 5 - Intake Camshaft Position Sensor 6 - Intake Camshaft Position Sensor Seal Ring 7 - Engine Front Cover 8 - Engine Front Cover Gasket 9 - Exhaust Camshaft Position Sensor Seal Ring 10 Exhaust Camshaft Position Sensor 11 - Exhaust Camshaft Position Sensor Bolt 12 - Engine Front Cover Oil Gallery Plug 13 - Engine Front Cover Oil Gallery Plug Seal Ring 14 - Oil Pressure Relief Valve Piston 15 - Oil Pressure Relief Valve Spring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2876 16 - Oil Pressure Relief Valve Plug 17 - Engine Front Cover Bolt (M10) 18 - Crankshaft Front Oil Seal 19 - Engine Front Cover Bolt (M6) 20 - Water Drain Plug Seal Ring 21 - Water Drain Plug 22 - Exhaust Camshaft Position Actuator Solenoid Valve Bolt Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2877 Camshaft Position Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Front (LUJ) 1 - Q6E Camshaft Position Actuator Solenoid Valve - Exhaust 2 - B23E Camshaft Position Sensor Exhaust 3 - B37 Engine Oil Pressure Switch 4 - B52A Heated Oxygen Sensor 1 5 - Q42 Turbocharger Wastegate Solenoid Valve 6 - Q2 A/C Compressor Clutch Engine Components - Right Rear (LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2878 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2879 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Open hood. Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 2. Disconnect the camshaft position sensor wiring harness plug (1). Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 3. Remove the camshaft position sensor bolt (3). 4. Remove the camshaft position sensor (2) and the seal ring (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2880 Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 1. Install the camshaft position sensor (2) and the seal ring (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 2. Install the camshaft position sensor bolt (3) and tighten to 8 Nm (71 lb in). Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 3. Connect the camshaft position sensor wiring harness plug (1). 4. After replacement of an camshaft position sensor, use a scan tool to speed up learn function. Refer to Engine Control Module Programming and Setup (LUW, LUJ) (See: Testing and Inspection/Programming and Relearning/Engine Control Module Programming and Setup) 5. Close hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Powertrain Component Views Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Powertrain Component Views Engine Components - Left Rear (LUJ) 1 - B111 Turbocharger Boost Pressure Sensor 2 - T8 Ignition Coil 3 - B68 Knock Sensor (KS) 4 Q38 Throttle Body 5 - B34 Engine Coolant Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Powertrain Component Views > Page 2885 Coolant Temperature Sensor/Switch (For Computer): Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components 1 - G105 Engine Compartment - Front Left 2 - G10 Cooling Fan Motor 3 - B34B Engine Coolant Temperature Sensor 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Engine Coolant Temperature Sensor Replacement (Radiator) Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement (Radiator) Engine Coolant Temperature Sensor Replacement (Radiator) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Engine Coolant Temperature Sensor Replacement (Radiator) > Page 2888 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement (Water Outlet) Engine Coolant Temperature Sensor Replacement (Water Outlet) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views Crankshaft Position Sensor: Locations Disassembled Views Disassembled Views Engine Block Assembly - 1.4L LDD 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Engine Block 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2893 16 - Oil Pan Bolt 17 - Oil Pan Drain Plug Seal Ring 18 - Oil Pan Drain Plug 19 - Crankshaft Position Sensor Bolt 20 - Crankshaft Position Sensor 21 - Crankshaft Position Sensor Seal Ring 22 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 23 - Crankshaft Position Sensor Reluctor Ring 24 Flywheel Bolt 25 - Engine Flywheel 26 - Crankshaft Rear Oil Seal 27 - Crankshaft Position Sensor Reluctor Ring Bolt 28 - Connecting Rod Bearing Cap Bolt 29 - Connecting Rod Bearing Cap 30 Lower Connecting Rod Bearing 31 - Upper Connecting Rod Bearing 32 - Connecting Rod 33 Piston Pin 34 - Piston 35 - Piston Oil Ring (With oil Ring Spacer) 36 - Lower Compression Ring 37 - Upper Compression Ring Engine Block Assembly - 1.4L LUH and LUJ Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2894 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Cylinder Head 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Baffle 16 - Oil Pan Baffle Bolt 17 - Oil Pan 18 - Oil Pan Bolt 19 - Oil Pan Drain Plug 20 - Crankshaft Position Sensor Bolt 21 - Crankshaft Position Sensor 22 - Crankshaft Position Sensor Seal Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2895 23 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 24 - Piston Oil Nozzle 25 - Crankshaft Position Sensor Reluctor Ring 26 - Crankshaft Position Sensor Reluctor Ring Bolt 27 - Crankshaft Rear Oil Seal 28 - Engine Flywheel (Two-Mass) 29 - Engine Flywheel Bolt 30 - Connecting Rod Bearing Cap Bolt 31 - Connecting Rod Bearing Cap 32 - Lower Connecting Rod Bearing 33 - Upper Connecting Rod Bearing 34 - Connecting Rod 35 - Piston Pin 36 - Piston Pin Retainer 37 - Piston Pin Retainer 38 - Piston 39 - Piston Oil Ring (With Oil Ring Spacer) 40 - Lower Compression Ring 41 - Upper Compression Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 2896 Crankshaft Position Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Rear (LUJ) 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2897 Crankshaft Position Sensor: Diagrams Component Connector End Views B26 Crankshaft Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2898 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The crankshaft position sensor system variation learn procedure is required when the following service procedures have been performed, regardless of whether DTC P0315 00 is set: * Engine replacement * Engine control module (ECM) replacement * Crankshaft damper replacement * Crankshaft replacement * Crankshaft Position Sensor Replacement * Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Note: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the crankshaft position sensor system variation learn procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * Crankshaft Position Sensor activity - If there is a crankshaft position sensor condition, refer to the applicable DTC that set. * Camshaft position signal activity - If there is a camshaft position sensor signal condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT) - If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P0315 00, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select the Crankshaft Position System Variation Learn procedure and perform the following: 1. Observe the fuel cut-off for the applicable engine. 2. Block the drive wheels. 3. Set the parking brake. 4. Place the vehicles transmission in Park or Neutral. 5. Turn the air conditioning (A/C) OFF. 6. Cycle the ignition from OFF to ON. 7. Apply and hold the brake pedal for the duration of the procedure. 8. Start and idle the engine. 9. Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 10. Release the throttle when fuel cut-off occurs. ‹› Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC P0315 00 ran and passed, the crankshaft position sensor variation learn procedure is complete. If the scan tool indicates DTC P0315 00 failed or did not run, refer to DTC P0315 (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 5. Turn OFF the ignition for 30 s after the learn procedure is completed successfully. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2899 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Wheels/Vehicle Underbody Component Views Fuel Tank Components 1 - B150 Fuel Tank Pressure Sensor 2 - A7 Fuel Pump and Level Sensor Assembly 3 - Q13 Evaporative Emission (EVAP) Vent Solenoid Valve Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2903 Fuel Level Sensor: Diagrams Component Connector End Views A7 Fuel Pump and Level Sensor Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2904 Fuel Level Sensor: Service and Repair Fuel Sender Assembly Replacement Removal Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning: Refer to Safety Goggles and Fuel Warning (See: Fuel Delivery and Air Induction/Service Precautions/Safety Goggles and Fuel Warning). Caution: Use care while handling the fuel sender to prevent damage and incorrect fuel level readings. 1. Remove the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Tank Fuel Pump Module Replacement). 2. Disconnect the fuel sender assembly wiring harness plugs (1). 3. Unclip the 2 fuel sender retainer pins. 4. Remove the fuel sender assembly (2). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2905 1. Install the fuel sender assembly (2). 2. Connect the fuel sender assembly wiring harness plugs (1). 3. Install the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Tank Fuel Pump Module Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations Wheels/Vehicle Underbody Component Views Fuel Tank Components 1 - B150 Fuel Tank Pressure Sensor 2 - A7 Fuel Pump and Level Sensor Assembly 3 - Q13 Evaporative Emission (EVAP) Vent Solenoid Valve Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2909 Fuel Tank Pressure Sensor: Diagrams Component Connector End Views B150 Fuel Tank Pressure Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Front of Vehicle/Engine Compartment Component Views Right Front of the Vehicle Components 1 of 2 1 - B75B Mass Air Flow/Intake Air Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views Knock Sensor: Locations Disassembled Views Disassembled Views Engine Block Assembly - 1.4L LDD 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Engine Block 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views > Page 2917 16 - Oil Pan Bolt 17 - Oil Pan Drain Plug Seal Ring 18 - Oil Pan Drain Plug 19 - Crankshaft Position Sensor Bolt 20 - Crankshaft Position Sensor 21 - Crankshaft Position Sensor Seal Ring 22 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 23 - Crankshaft Position Sensor Reluctor Ring 24 Flywheel Bolt 25 - Engine Flywheel 26 - Crankshaft Rear Oil Seal 27 - Crankshaft Position Sensor Reluctor Ring Bolt 28 - Connecting Rod Bearing Cap Bolt 29 - Connecting Rod Bearing Cap 30 Lower Connecting Rod Bearing 31 - Upper Connecting Rod Bearing 32 - Connecting Rod 33 Piston Pin 34 - Piston 35 - Piston Oil Ring (With oil Ring Spacer) 36 - Lower Compression Ring 37 - Upper Compression Ring Engine Block Assembly - 1.4L LUH and LUJ Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views > Page 2918 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Cylinder Head 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Baffle 16 - Oil Pan Baffle Bolt 17 - Oil Pan 18 - Oil Pan Bolt 19 - Oil Pan Drain Plug 20 - Crankshaft Position Sensor Bolt 21 - Crankshaft Position Sensor 22 - Crankshaft Position Sensor Seal Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views > Page 2919 23 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 24 - Piston Oil Nozzle 25 - Crankshaft Position Sensor Reluctor Ring 26 - Crankshaft Position Sensor Reluctor Ring Bolt 27 - Crankshaft Rear Oil Seal 28 - Engine Flywheel (Two-Mass) 29 - Engine Flywheel Bolt 30 - Connecting Rod Bearing Cap Bolt 31 - Connecting Rod Bearing Cap 32 - Lower Connecting Rod Bearing 33 - Upper Connecting Rod Bearing 34 - Connecting Rod 35 - Piston Pin 36 - Piston Pin Retainer 37 - Piston Pin Retainer 38 - Piston 39 - Piston Oil Ring (With Oil Ring Spacer) 40 - Lower Compression Ring 41 - Upper Compression Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views > Page 2920 Knock Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Left Rear (LUJ) 1 - B111 Turbocharger Boost Pressure Sensor 2 - T8 Ignition Coil 3 - B68 Knock Sensor (KS) 4 Q38 Throttle Body 5 - B34 Engine Coolant Temperature Sensor Lower Rear of the Engine Components 1 of 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Disassembled Views > Page 2921 1 - B68 Knock Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2922 Knock Sensor: Description and Operation Knock Sensor System Description Circuit/System Description The knock sensor system enables the engine control module (ECM) to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The ECM uses the knock sensor system to test for abnormal engine noise that may indicate detonation, also known as spark knock. Sensor Description This knock sensor system uses one or two flat response dual-wire sensors. The sensor uses piezo-electric crystal technology that produces an alternating current (AC) voltage signal of varying amplitude and frequency based on the engine vibration or noise level. The amplitude and frequency are dependant upon the level of knock that the knock sensor detects. The ECM receives the knock sensor signal through 2 isolated signal circuits. If the ECM has determined that knock is present, it will retard the ignition timing to attempt to reduce the knock. The ECM is capable of controlling spark retard on an individual cylinder basis. The ECM will always try to work back to a zero compensation level, or no spark retard. knock sensor diagnostics are calibrated to detect faults with the knock sensor circuitry inside the ECM, the knock sensor wiring, or the knock sensor voltage output. Some diagnostics are also calibrated to detect constant noise from an outside influence such as a loose/damaged component or excessive mechanical engine noise. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2923 Knock Sensor: Service and Repair Knock Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Disassembled Views Manifold Pressure/Vacuum Sensor: Locations Disassembled Views Disassembled Views Intake Manifold Assembly - 1.4L LUH and LUJ 1 - Fuel Injector Fuel Rail 2 - Fuel Injector Fuel Rail Bolt 3 - Manifold Absolute Pressure Sensor 4 Manifold Absolute Pressure Sensor Bolt 5 - Evaporative Emission Canister Purge Solenoid Valve 6 - Intake Manifold 7 - Throttle Body Seal Ring 8 - Throttle Body 9 - Throttle Body Bolt 10 - Intake Manifold Gasket Intake Manifold Assembly - 1.4L LDD Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Disassembled Views > Page 2928 1 - Intake Manifold Sealings 2 - Intake Manifold (With Intake Manifold Runner and Intake Manifold Runner Valve) 3 - Throttle Body Bolt 4 - Throttle Body 5 - Throttle Body Seal Ring 6 - Fuel Injection Fuel Rail Bolt 7 - Evaporative Emission Canister Purge Solenoid Valve 8 - Evaporative Emission Canister Purge Solenoid Valve Rubber 9 - Evaporative Emission Canister Purge Solenoid Valve Bracket Bolt 10 - Evaporative Emission Canister Purge Solenoid Valve Bracket 11 - Fuel Injection Fuel Rail 12 - Fuel Injector Retainer Clamp 13 - Fuel Injector 14 - Manifold Absolute Pressure Sensor Bolt 15 - Manifold Absolute Pressure Sensor 16 - Manifold Absolute Pressure Sensor Seal Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Disassembled Views > Page 2929 Manifold Pressure/Vacuum Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Rear (LUJ) 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2930 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Disassembled Views Oxygen Sensor: Locations Disassembled Views Disassembled Views Exhaust Side - 1.4L LUH and LUJ 1 - Positive Crankcase Ventilation Pipe Assembly 2 - Exhaust Manifold Gasket 3 - Turbo Charger Oil Feed Pipe Hollow Screw 4 - Turbo Charger Oil Feed Pipe 5 - Turbo Charger Oil Feed Pipe Bolt 6 - Oil Cooler Coolant Outlet Hose 7 - Oil Cooler Coolant Outlet Hose Clamp 8 - Oil Cooler Coolant Feed Pipe Bolt 9 - Oil Cooler Coolant Feed Pipe 10 - Engine Oil Cooler Assembly 11 - Catalytic Converter Bracket 12 - Catalytic Converter to Catalytic Converter Bracket Nut 13 - Turbocharger Coolant Return Pipe 14 - Turbocharger Coolant Feed Pipe Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Disassembled Views > Page 2935 15 - Turbocharger Coolant Feed Pipe Hollow Screw 16 - Heated Oxygen Sensor 1 17 - Catalytic Converter 18 - Catalytic Converter Heat Shield 19 - Catalytic Converter Heat Shield Bolt 20 - Catalytic Converter Seal 21 - Catalytic Converter V-Clamp 22 - Turbocharger Oil Return Pipe 23 Turbocharger Oil Return Pipe Bolt 24 - Exhaust Manifold Heat Shield 25 - Exhaust Manifold Heat Shield Bolt 26 - Turbocharger (with Exhaust Manifold) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Disassembled Views > Page 2936 Oxygen Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Front (LUJ) 1 - Q6E Camshaft Position Actuator Solenoid Valve - Exhaust 2 - B23E Camshaft Position Sensor Exhaust 3 - B37 Engine Oil Pressure Switch 4 - B52A Heated Oxygen Sensor 1 5 - Q42 Turbocharger Wastegate Solenoid Valve 6 - Q2 A/C Compressor Clutch Engine Components - Right Rear (LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Disassembled Views > Page 2937 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Caution > Page 2940 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Caution > Page 2941 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Sensor 1 Heated Oxygen Sensor Replacement - Sensor 1 (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor Replacement - Sensor 1 > Page 2944 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Sensor 2 Heated Oxygen Sensor Replacement - Sensor 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair Transmission Position Switch/Sensor: Service and Repair Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Special Tools DT-41229 - Manual Shaft Pin Installer For equivalent regional tools, refer to Special Tools (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Tools and Equipment). Removal Procedure 1. Remove the control valve body. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 2. Remove the manual shaft detent lever hub pin (1) using a pry bar and pliers. 3. Remove and DISCARD the manual shift shaft pin (5). 4. Remove the manual shaft (2). 5. Disconnect the actuator rod (3) from the detent lever assembly. Do not remove the actuator rod from the transmission case. 6. Remove the manual shaft detent (with shift position switch) lever assembly (4). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Page 2948 1. Connect the actuator rod (3) to the detent lever assembly. 2. Install the manual shaft detent (with shift position switch) lever assembly (4). 3. Install the manual shaft (2). 4. Install the manual shaft detent lever hub pin (1) to height of 7.9 mm (0.38 in) (b). Caution: Use J 41229 to install the manual shaft pin at the correct height in order to properly secure the manual shaft. If you install the pin too deep, the case bore may crack. 5. Install the NEW manual shift shaft pin (5) using DT-41229 - pin installer. Use a NEW pin to ensure proper engagement with the case. 6. Inspect pin installed height is within 7.2-8.2 mm (0.28-0.32 in) (a). 7. Install the control valve body. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 8. Perform the transmission adaptive values learn procedure. Refer to Transmission Adaptive Values Learn (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair Transmission Position Switch/Sensor: Service and Repair Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Special Tools DT-41229 - Manual Shaft Pin Installer For equivalent regional tools, refer to Special Tools (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Tools and Equipment). Removal Procedure 1. Remove the control valve body. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 2. Remove the manual shaft detent lever hub pin (1) using a pry bar and pliers. 3. Remove and DISCARD the manual shift shaft pin (5). 4. Remove the manual shaft (2). 5. Disconnect the actuator rod (3) from the detent lever assembly. Do not remove the actuator rod from the transmission case. 6. Remove the manual shaft detent (with shift position switch) lever assembly (4). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Page 2952 1. Connect the actuator rod (3) to the detent lever assembly. 2. Install the manual shaft detent (with shift position switch) lever assembly (4). 3. Install the manual shaft (2). 4. Install the manual shaft detent lever hub pin (1) to height of 7.9 mm (0.38 in) (b). Caution: Use J 41229 to install the manual shaft pin at the correct height in order to properly secure the manual shaft. If you install the pin too deep, the case bore may crack. 5. Install the NEW manual shift shaft pin (5) using DT-41229 - pin installer. Use a NEW pin to ensure proper engagement with the case. 6. Inspect pin installed height is within 7.2-8.2 mm (0.28-0.32 in) (a). 7. Install the control valve body. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 8. Perform the transmission adaptive values learn procedure. Refer to Transmission Adaptive Values Learn (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle Variable Valve Timing Actuator: Customer Interest Engine - Lack of Power with Multiple DTCs or Rattle TECHNICAL Bulletin No.: 10-06-04-016 Date: December 20, 2010 Subject: Engine Lack of Power with DTCs P0011, P0014, P000A, P000B, P0012, P0015 or Engine Rattle Noise (Remove Oil Filters from Intake and Exhaust Camshaft Position Actuator Solenoid Valves) Models: 2008-2011 Chevrolet Aveo 2011 Chevrolet Cruze (US and Canada) 2009-2011 Chevrolet Cruze (Export Only) 2008-2009 Pontiac G3, Wave 2008-2009 Saturn Astra Condition Some customers may comment on lack of power with the following DTCs or an engine rattle noise from the sprockets. Cruze GEN3 1.6/1.8D - P0011: Intake Camshaft Position (CMP) System Performance - P0014: Exhaust Camshaft Position (CMP) System Performance - P000A: Intake Camshaft Position System Slow Response - P000B: Exhaust Camshaft Position System Slow Response Aveo GEN3 1.4D - P0012: Intake Camshaft Position (CMP) System Performance Bank 1-Retarded - P0015: Exhaust Camshaft Position (CMP) System Performance Bank 1-Retarded Aveo/G3/Wave Gen3 1.6D - P0011: Intake Camshaft Position (CMP) System Performance Bank 1 - P0014: Exhaust Camshaft Position (CMP) System Performance Bank 1 Correction Remove four oil filters from the intake and exhaust camshaft position actuator solenoid valves. 1. Open the hood. 2. Disconnect the negative battery cable. 3. Disconnect the camshaft position actuator solenoid valve connectors. 4. Remove the power steering line bracket bolt and reposition the bracket (for 1.6/1.8L only). 5. Disconnect PCV pipe and reposition (for 1.6/1.8L only). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 2961 6. Remove the camshaft position actuator solenoid valve bolts. 7. Remove the camshaft position actuator solenoid valves and seals. 8. Check whether the filter is broken or not (1). 9. Remove the four filters (intake and exhaust). 1. Broken Filter: Remove filter with a blunt tool. 2. Unbroken Filter 1. Locate the filter hinge between the holes. 2. Cut the filter hinge slightly. Caution Do not scratch the valve surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 2962 3. Remove the filter with a blunt tool. 10. Install the camshaft position actuator solenoid valves and seals. Coat the seal with clean engine oil prior to installation. 11. Install the camshaft position actuator solenoid valve bolts. Tighten Tighten the bolts to 6 Nm (53 lb in). 12. Connect the camshaft position actuator solenoid valve connectors. 13. Reposition and install the PCV pipe (for 1.6/1.8 only). 14. Reposition the power steering bracket and install the power steering line bracket bolt (for 1.6/1.8 only). 15. Connect the negative battery cable. Note If an engine rattle noise is heard after removing the filters, refer to SI for further diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle Variable Valve Timing Actuator: All Technical Service Bulletins Engine - Lack of Power with Multiple DTCs or Rattle TECHNICAL Bulletin No.: 10-06-04-016 Date: December 20, 2010 Subject: Engine Lack of Power with DTCs P0011, P0014, P000A, P000B, P0012, P0015 or Engine Rattle Noise (Remove Oil Filters from Intake and Exhaust Camshaft Position Actuator Solenoid Valves) Models: 2008-2011 Chevrolet Aveo 2011 Chevrolet Cruze (US and Canada) 2009-2011 Chevrolet Cruze (Export Only) 2008-2009 Pontiac G3, Wave 2008-2009 Saturn Astra Condition Some customers may comment on lack of power with the following DTCs or an engine rattle noise from the sprockets. Cruze GEN3 1.6/1.8D - P0011: Intake Camshaft Position (CMP) System Performance - P0014: Exhaust Camshaft Position (CMP) System Performance - P000A: Intake Camshaft Position System Slow Response - P000B: Exhaust Camshaft Position System Slow Response Aveo GEN3 1.4D - P0012: Intake Camshaft Position (CMP) System Performance Bank 1-Retarded - P0015: Exhaust Camshaft Position (CMP) System Performance Bank 1-Retarded Aveo/G3/Wave Gen3 1.6D - P0011: Intake Camshaft Position (CMP) System Performance Bank 1 - P0014: Exhaust Camshaft Position (CMP) System Performance Bank 1 Correction Remove four oil filters from the intake and exhaust camshaft position actuator solenoid valves. 1. Open the hood. 2. Disconnect the negative battery cable. 3. Disconnect the camshaft position actuator solenoid valve connectors. 4. Remove the power steering line bracket bolt and reposition the bracket (for 1.6/1.8L only). 5. Disconnect PCV pipe and reposition (for 1.6/1.8L only). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 2968 6. Remove the camshaft position actuator solenoid valve bolts. 7. Remove the camshaft position actuator solenoid valves and seals. 8. Check whether the filter is broken or not (1). 9. Remove the four filters (intake and exhaust). 1. Broken Filter: Remove filter with a blunt tool. 2. Unbroken Filter 1. Locate the filter hinge between the holes. 2. Cut the filter hinge slightly. Caution Do not scratch the valve surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 2969 3. Remove the filter with a blunt tool. 10. Install the camshaft position actuator solenoid valves and seals. Coat the seal with clean engine oil prior to installation. 11. Install the camshaft position actuator solenoid valve bolts. Tighten Tighten the bolts to 6 Nm (53 lb in). 12. Connect the camshaft position actuator solenoid valve connectors. 13. Reposition and install the PCV pipe (for 1.6/1.8 only). 14. Reposition the power steering bracket and install the power steering line bracket bolt (for 1.6/1.8 only). 15. Connect the negative battery cable. Note If an engine rattle noise is heard after removing the filters, refer to SI for further diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Page 2970 Variable Valve Timing Actuator: Description and Operation Camshaft Actuator System Description Circuit/System Description The camshaft position actuator solenoid valve - intake and camshaft position actuator solenoid valve - exhaust system enables the engine control module (ECM) to change camshaft timing while the engine is running. The camshaft position actuator assembly varies camshaft position in response to directional changes in oil pressure. The camshaft position actuator solenoid valve Intake and camshaft position actuator solenoid valve - exhaust controls the oil pressure that is applied to advance or retard the camshaft. Modifying camshaft timing under changing engine demand provides better balance between the following performance concerns: * Engine power output * Fuel economy * Lower exhaust emissions The camshaft position actuator solenoid valve - intake and camshaft position actuator solenoid valve - exhaust is controlled by the ECM. The crankshaft position sensor and the camshaft position sensor - intake and camshaft position sensor - exhaust are used to monitor changes in camshaft position. The ECM uses information from the following sensors in order to calculate the desired camshaft position: * Engine coolant temperature (ECT) sensor * Mass air flow (MAF) sensor * Throttle position sensor * Vehicle speed sensor (VSS) Camshaft Position Actuator System Operation The ECM operates the camshaft position actuator solenoid valve - intake and camshaft position actuator solenoid valve - exhaust by pulse width modulation (PWM) of the solenoid coil. The higher the PWM duty cycle, the larger the change in camshaft timing. Oil pressure that is applied to the advance side of the fixed vanes will rotate the camshaft in a clockwise direction. The clockwise movement of the camshaft will advance the timing up to a maximum of 21°. When oil pressure is applied to the return side of the vanes, the camshaft will rotate counterclockwise until returning to 0°. Oil flowing to the camshaft position actuator solenoid valve - intake and camshaft position actuator solenoid valve - exhaust housing from the camshaft position actuator solenoid valve - Intake and camshaft position actuator solenoid valve - exhaust advance passage applies pressure to the advance side of the vane wheel in the camshaft position actuator assembly. At the same time the camshaft position actuator solenoid valve - Intake and camshaft position actuator solenoid valve exhaust retard passage is open, allowing oil pressure to decrease on the retard side of the vane wheel. These two simultaneous actions cause the vane wheel to rotate clockwise, advancing camshaft advance timing. When the oil flowing to the camshaft position actuator solenoid valve - Intake and camshaft position actuator solenoid valve - exhaust housing is from the camshaft position actuator solenoid valve Intake and camshaft position actuator solenoid valve - exhaust retard passage, oil pressure is applied to the retard side of the vane wheel. Because the solenoid advance passage is open, allowing oil pressure to decrease on the advance side of the vane wheel, the camshaft position retards. The ECM can also command the camshaft position actuator solenoid valve - Intake and camshaft position actuator solenoid valve - exhaust to stop oil flow from both passages in order to hold the current camshaft position. The ECM is continuously comparing camshaft position sensor - intake and camshaft position sensor - exhaust input with camshaft position actuator solenoid valve Intake and camshaft position actuator solenoid valve - exhaust input in order to monitor camshaft position and detect any system malfunctions. The following table provides camshaft phase commands for common driving conditions: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Service and Repair Variable Valve Timing Solenoid: Service and Repair Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure 1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.4L LUH and LUJ) (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair). 2. Disconnect the intake camshaft position actuator solenoid valve wiring harness plug (3). 3. Disconnect the exhaust camshaft position actuator solenoid valve wiring harness plug (2). 4. Unclip ECM wiring harness (1) from camshaft cover. 5. Remove the 4 camshaft position actuator solenoid valve bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Service and Repair > Page 2974 6. Carefully rotate the intake camshaft position actuator solenoid valve (1) counter clockwise as shown. 7. Carefully rotate the exhaust camshaft position actuator solenoid valve (2) clockwise as shown. Caution: The camshaft position actuator solenoid valves must be kept parallel to the engine front cover during removal and installation. The camshaft position actuator solenoid valves can be damaged if they become wedged or stuck during this process. 8. Carefully remove the 2 camshaft position actuator solenoid valves (2) and the seal rings (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Service and Repair > Page 2975 Caution: The camshaft position actuator solenoid valves must be kept parallel to the engine front cover during removal and installation. The camshaft position actuator solenoid valves can be damaged if they become wedged or stuck during this process. Note: Lubricate the seal rings with oil in order to make the installation easier. 1. Carefully install the 2 camshaft position actuator solenoid valves (2) and the 2 seal rings (1) by gently pressing into position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 4 camshaft position actuator solenoid valve bolts (1) and tighten to 8 Nm (71 lb in). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Service and Repair > Page 2976 3. The 2 camshaft position actuator solenoid valves should be installed in the position as shown (1) and (2). 4. Clip ECM wiring harness (1) to camshaft cover. 5. Connect the exhaust camshaft position actuator solenoid valve wiring harness plug (2). 6. Connect the intake camshaft position actuator solenoid valve wiring harness plug (3). 7. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.4L LUH and LUJ) (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Service and Repair Catalyst Shield: Service and Repair Catalytic Converter Heat Shield Replacement (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Service and Repair Canister Purge Solenoid: Service and Repair Evaporative Emission Canister Purge Solenoid Valve Replacement (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Diagrams Canister Vent Valve: Diagrams Component Connector End Views Q13 Evaporative Emission Vent Solenoid Valve Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair PCV Valve Hose: Service and Repair Positive Crankcase Ventilation Hose/Pipe/Tube Replacement Removal Procedure 1. Open the hood. 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (1.4L LUH and LUJ) (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 3. Open the 2 positive crankcase ventilation pipe retainer clips (2) and (3). Note: Move retainer clamp (1) in direction of the arrow. 4. Remove the positive crankcase ventilation pipe from the intake manifold. 5. Loosen the charger air bypass valve pipe clamp (3). 6. Remove the charger air bypass valve pipe from turbocharger. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair > Page 2994 7. Remove the charger air bypass valve pipe (2) from turbo charger wastegate regulator solenoid valve. 8. Disconnect the positive crankcase ventilation pipe from turbocharger. 9. Unclip and remove the positive crankcase ventilation pipe assembly (1) from the camshaft cover retainer clips. Installation Procedure 1. Install the positive crankcase ventilation pipe assembly (1) to the camshaft cover retainer clips. 2. Connect the positive crankcase ventilation pipe to turbocharger. 3. Install the charger air bypass valve pipe (2) to turbo charger wastegate regulator solenoid valve. 4. Install the charger air bypass valve pipe to turbocharger. 5. Fasten the charger air bypass valve pipe clamp (3). 6. Install the positive crankcase ventilation pipe to the intake manifold and fix with retainer clamp (1). 7. Clip in the positive crankcase ventilation pipe to the 2 retainer clips (2) and (3). 8. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (1.4L LUH and LUJ) (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURE Fuel Pressure (Key ON, Engine OFF).................................................................................................. .............................................250-450 kPa (36-65 PSI) Should not decrease greater than........................................................................................................ .................................................34 kPa (5 PSI) in 1 min Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 2999 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description When the ignition is turned ON, the engine control module (ECM) supplies power to the in-tank fuel pump, by energizing the fuel pump relay. The in-tank fuel pump remains ON as long as the engine is cranking or running and the ECM receives crankshaft reference pulses. If there are no reference pulses, the ECM turns the in-tank fuel pump OFF, 2 s after the ignition switch is turned ON or 2 s after the engine stops running. The electric fuel pump is incorporated into the modular fuel pump and sender assembly and is located inside the fuel tank. The fuel pump supplies fuel through a fuel filter, also located in the modular fuel pump and sender assembly, through the fuel feed pipes, to the fuel rail assembly. The fuel pump provides fuel at a pressure above the pressure needed by the fuel injectors. The fuel pressure regulator, located in the modular fuel pump and sender assembly, keeps the fuel available to the fuel injectors at a regulated pressure. When the fuel pressure rises above the pressure regulator calibration, the pressure is relieved, with excess fuel exhausted into the modular fuel pump and sender assembly reservoir. Reference Information Description and Operation Fuel System Description (See: Computers and Control Systems/Description and Operation/Fuel System Description) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Special Tools * CH 48027 - Digital Pressure Gauge * EN 37287 - Fuel Line Shut-Off Adapters For equivalent regional tools, refer to Special Tools (See: Computers and Control Systems/Tools and Equipment). Circuit/System Verification Note: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that an adequate amount of fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. 1. Ignition ON, command the KR23A Fuel Pump Relay ON with a scan tool. You should hear the G12 Fuel Pump turn ON and OFF. ‹› If the G12 Fuel Pump does not turn ON, refer to Fuel Pump Electrical Circuit Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Pump Electrical Circuit Diagnosis). 2. Ignition OFF, all accessories OFF, install the CH 48027 - Digital Pressure Gauge. 3. Ignition ON, command the KR23A Fuel Pump Relay ON with a scan tool. Verify the fuel pressure is between 250-450 kPa (36-65 PSI) and remains steady for 5 m. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 3002 Circuit/System Testing Note: * The KR23A Fuel Pump Relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Do not start the engine. 1. Ignition ON, engine OFF, command the KR23A Fuel Pump Relay ON with a scan tool and observe the fuel pressure gauge while the G12 Fuel Pump is operating. Verify the fuel pressure is between 250-450 kPa (36-65 PSI). ‹› If the fuel pressure is greater than the specified range, replace the G12 Fuel Pump. ‹› If the fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all items test normal, replace the G12 Fuel Pump. * Restricted fuel feed pipe * Restricted or clogged strainer * Restricted or plugged fuel filter * Inspect the G12 Fuel Pump harness connectors and the ground circuits of the fuel pump for poor connections. Note: The fuel pressure may vary slightly when the G12 Fuel Pump stops operating. After the G12 Fuel Pump stops operating, the fuel pressure should stabilize and remain constant. 2. Verify the fuel pressure does not decrease greater than 34 kPa (5 PSI) in 1 min. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve fuel pressure. 2. Install the EN 37287 - Fuel Line Shut-Off Adapters between the fuel feed pipe and the fuel rail. 3. Open the valve on the EN 37287 - Fuel Line Shut-Off Adapters. 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the digital pressure gauge. 5. Close the valve on the EN 37287 - Fuel Line Shut-Off Adapters. 6. Verify the fuel pressure does not decrease greater than 34 kPa (5 PSI) in 1 minute. ‹› If the fuel pressure decreases more than 34 kPa (5 PSI) within the specified time, locate and replace the leaking fuel injector(s). ‹› If the fuel pressure does not decrease more than 34 kPa (5 PSI) within the specified time, replace the G12 Fuel Pump. 3. Relieve the fuel pressure to 69 kPa (10 PSI). Verify that the fuel pressure does not decrease more than 14 kPa (2 PSI) in 5 min. ‹› If the fuel pressure decreases more than the specified value, replace the G12 Fuel Pump. 4. Remove the EN 37287 - Fuel Line Shut-Off Adapters and CH 48027 - Digital Pressure Gauge. 5. Operate the vehicle within the conditions of the customers concern while monitoring fuel related parameters with a scan tool. The scan tool parameters should not indicate a lean condition. ‹› If the scan tool parameters indicate a lean condition, test for a restricted fuel feed pipe, restricted fuel filter, or poor connections at the harness connectors and ground circuits of the fuel pump. If all test normal, replace the fuel pump. 6. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls). Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 3003 Fuel Pressure: Testing and Inspection Fuel Pressure Measurement Fuel Pressure Measurement Special Tools EN-34730-91 - Pressure Tester For equivalent regional tools, refer to Special Tools (See: Computers and Control Systems/Tools and Equipment) Warning Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Remove the protective cap from the test connection. 2. Attach the EN-34730-91 - tester (1) to the test connection. 3. Start the engine. * Bleed the pressure tester at idling speed. * Collect the exiting fuel in a suitable container. * Read the fuel pressure from the pressure gauge. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 4. Detach the pressure gauge EN-34730-91 - tester from the test connection. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Special Tools EN-34730-91 - Pressure Tester For equivalent regional tools, refer to Special Tools (See: Computers and Control Systems/Tools and Equipment). Warning Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. Warning Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Remove the fuel injector rail cap (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Page 3007 2. Relieve the fuel pressure. Use EN-34730-91 - pressure tester (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > System Diagnosis Idle Speed: Testing and Inspection Throttle/Idle Learn The Idle Learn Procedure listed below must be performed whenever the following occurs: The crankshaft position variation learn procedure is also required when the following service procedures have been performed, regardless of whether or not DTC P0315 00 is set: * The throttle body assembly is replaced. * The throttle body is cleaned. * The engine control module (ECM) is replaced. * The idle air control valve is replaced. * Power disconnection (battery cable, ECM fuse, etc.) (Delphi ECM only) 1. Turn the ignition ON. 2. Turn the ignition OFF for 15 s. 3. Turn the ignition ON for 5 s. 4. Turn the ignition OFF for 15 s. 5. Start the engine in park/neutral. 6. Allow the engine to run until the engine coolant temperature is greater than 85°C (185°F). 7. Turn the A/C ON for 10 s, if equipped. 8. If the vehicle is equipped with an automatic transaxle, apply the parking brake. While pressing the brake pedal, place the transaxle in drive for 10 s. 9. Turn the A/C OFF for 10 s, if equipped. 10. If the vehicle is equipped with an automatic transaxle, while pressing the brake pedal, place the transaxle in park/neutral. 11. Turn the ignition OFF. The idle learn procedure is complete. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3014 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views B107 Accelerator Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3015 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 3021 Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Inlet Duct Replacement Air Cleaner Inlet Duct Replacement Removal Procedure 1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 2. Remove the intake air duct bolt (2). 3. Remove the intake air duct (1) Installation Procedure 1. Install the intake air duct (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 3022 2. Install and tighten the intake air duct bolt (2). 3. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement (1.4L LUH and LUJ) Removal Procedure 1. Open hood. 2. Disconnect mass air flow sensor wiring harness plug (2) from mass air flow sensor (3). 3. Unclip mass air flow sensor wiring harness retainer clip from air cleaner housing (1). 4. Remove the air cleaner outlet duct clamp (3). 5. Remove the air cleaner outlet duct (2) from air cleaner housing (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 3026 6. Remove the 5 air cleaner housing bolts (1). 7. Remove the air cleaner upper housing (2) from the air cleaner lower housing (4). 8. Remove the air cleaner element (3). Installation Procedure 1. Install the air cleaner element (3). 2. Install the air cleaner upper housing (2) to the air cleaner lower housing (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 5 air cleaner housing bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 3027 4. Install the air cleaner outlet duct (2) to the air cleaner housing (1). 5. Install the air cleaner outlet duct clamp (3). 6. Clip in mass air flow sensor wiring harness retainer clip to air cleaner housing (1). 7. Connect the mass air flow sensor wiring harness plug 2) to the mass air flow sensor (3). 8. Close hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Right Front of the Vehicle Components 1 of 2 1 - B75B Mass Air Flow/Intake Air Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3031 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor Replacement (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. Fuel: Technical Service Bulletins Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. INFORMATION Bulletin No.: 10-06-04-015 Date: December 08, 2010 Subject: General Motors' Position Regarding Use of E15 in Model Year 2007 and Newer Vehicles Models: 2007-2011 GM Passenger Cars and Trucks General Motors' position regarding the Environmental Protection Agency announcement allowing the use of E 15 in 2007 and newer vehicles: - General Motors' remains focused on securing a safe and positive driving experience for our customers. GM believes that the waiver decision by the EPA regarding E 15 could lead to confusion for consumers as to what fuel their vehicle should use. In response, we will continue to encourage our customers to refer to their vehicle Owner Manual for proper fuel designation. The vehicle Owner Manual specifies that fuels containing more than 10 percent ethanol should not be used in GM vehicles that do not have a flex fuel designation. - GM has the largest fleet of flex fuel vehicles on the road today (over 4 million in the U.S.) and these vehicles can safely use ethanol blends of up to 85 percent ethanol. So blends of E 15 (15 percent ethanol), as in the partial waiver announced, are appropriate for these vehicles. However, ethanol blends greater than E 10 should not be used in GM vehicles that do not have a flex fuel designation as they are not designed and certified to run on gasoline consisting of more than 10 percent ethanol-blend volume to avoid any unintended consequences, as per: their Owner Manual. - We believe biofuels, especially E 85 ethanol, are an effective near-term solution to reduce petroleum dependence and the carbon footprint of driving. As the global leader in producing vehicles designed to handle ethanol blends from E 0 to E 85, GM offers 19 flexible-fuel vehicles for the 2011 model year. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 3036 Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 3037 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 3038 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 3039 Fuel: Service Precautions Gasoline/Gasoline Vapors Warning Warning Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 3040 Fuel: Testing and Inspection Alcohol/Contaminants-in-Fuel Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Test Description Water contamination in the fuel system may cause driving conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust or deterioration. Ethanol concentrations of greater than 10% can cause driveability conditions and fuel system deterioration. Fuel with more than 10% ethanol may result in driveability conditions such as hesitation, lack of power, stalling, or no start. Excessive concentrations of ethanol used in vehicles not designed for this type of propellant may cause fuel system corrosion, deterioration of rubber components, and fuel filter restriction. Reference Information Special Tools CH 44175 - Fuel Compression Tester For equivalent regional tools, refer to Special Tools (See: Computers and Control Systems/Tools and Equipment). System Verification The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If the sample appears cloudy, or contaminated with water, as indicated by a water layer at the bottom of the sample, perform the particulate contaminants in fuel testing procedure. If alcohol contamination is suspected, perform the alcohol in fuel testing procedure. System Testing Alcohol in Fuel Testing with Special Tool 1. Test the fuel composition using CH 44175 - fuel compression tester and instruction manual. 2. If water appears in the fuel sample, clean the fuel system. 3. Subtract 50 from the reading on the DMM in order to obtain the percentage of alcohol in the fuel sample. 4. If the fuel sample contains more than 15% ethanol, add fresh, regular gasoline to the vehicles fuel tank. 5. Test the fuel composition. 6. If testing shows the ethanol percentage is still more than 15%, replace the fuel in the vehicle. Alcohol in Fuel Testing without Special Tool 1. Using a 100 ml specified cylinder with 1 ml graduation marks, fill the cylinder with fuel to the 90 ml mark. 2. Add 10 ml of water in order to bring the total fluid volume to 100 ml and install a stopper. 3. Shake the cylinder vigorously for 10-15 s. 4. Carefully loosen the stopper in order to release the pressure. 5. Reinstall the stopper and shake the cylinder vigorously again for 10-15 s. 6. Put the cylinder on a level surface for approximately 5 min in order to allow adequate liquid separation. If alcohol is present in the fuel, the volume of the lower layer, which may now contain both alcohol and water, will be more than 10 ml. For example, if the volume of the lower layer is increased to 15 ml, this indicates at least 5% alcohol in the fuel. The actual amount of alcohol may be somewhat more because this procedure does not extract all of the alcohol from the fuel. Particulate Contaminants in Fuel Testing Procedure 1. Using an approved fuel container, draw approximately 0.5 L of fuel. 2. Place the container on a level surface for approximately 5 min in order to allow for the particulate contamination to settle. Particulate contamination will show up in various shapes and colors. Sand will typically be identified by white or light brown crystals. Rubber will appear as Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 3041 black and irregular particles. 3. Observe the fuel sample. If any physical contaminants or water are present, clean the fuel system. Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Special Tools EN-34730-91 - Pressure Tester For equivalent regional tools, refer to Special Tools (See: Computers and Control Systems/Tools and Equipment). Warning Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. Warning Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Remove the fuel injector rail cap (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 3046 2. Relieve the fuel pressure. Use EN-34730-91 - pressure tester (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Fuel Heater Relay > Component Information > Locations Fuel Heater Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Fuel Heater Relay > Component Information > Locations > Page 3051 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Fuel Heater Relay > Component Information > Locations > Page 3052 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Fuel Heater Relay > Component Information > Locations > Page 3053 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Circuit Diagnosis Fuel Injector: Testing and Inspection Fuel Injector Circuit Diagnosis Fuel Injector Circuit Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The engine control module (ECM) enables the appropriate fuel injector pulse for each cylinder. Ignition voltage is supplied to the fuel injectors. The ECM controls each fuel injector by grounding the control circuit via a solid state device called a driver. Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) Special Tools EL 35616-E - GM-Approved Terminal Test Kit Includes J 35616-200 Test Light Probe Kit For equivalent regional tools, refer to Special Tools (See: Computers and Control Systems/Tools and Equipment). Circuit/System Testing Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Circuit Diagnosis > Page 3058 1. Ignition OFF, disconnect the harness connector at the appropriate fuel injector listed below: * Q17A Fuel Injector 1 * Q17B Fuel Injector 2 * Q17C Fuel Injector 3 * Q17D Fuel Injector 4 2. Ignition ON, verify that a test lamp illuminates between the appropriate Q17 Fuel Injector ignition circuit terminal 1 and ground. ‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, test or replace the Q17 Fuel Injector. 3. Ignition OFF, connect a J 35616-200 - test light probe kit between the K20 Engine Control Module control circuit terminal 2 and the ignition circuit terminal 1 of each Q17 Fuel Injector one at a time. 4. Engine cranking, the test lamp should flash for each injector. ‹› If the test lamp is always ON, test the appropriate K20 Engine Control Module control circuit for a short to ground. If the circuit tests normal, replace the K20 Engine Control Module. ‹› If the test lamp is always OFF, test the appropriate K20 Engine Control Module control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the K20 Engine Control Module. 5. If all circuits test normal, test or replace the appropriate Q17 Fuel Injector. Refer to Fuel Injector Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Injector Diagnosis). Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Injector Replacement (See: Service and Repair) * Control Module References (See: Testing and Inspection/Programming and Relearning)for ECM replacement, setup, and programming Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Circuit Diagnosis > Page 3059 Fuel Injector: Testing and Inspection Fuel Injector Diagnosis Fuel Injector Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description The control module enables the appropriate fuel injector pulse for each cylinder. The ignition voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect the engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases. When performing the fuel injector balance test, the scan tool is first used to energize the fuel pump. The fuel injector tester is then used to pulse each injector for a precise amount of time, allowing a measured amount of the fuel to be injected. This causes a drop in the system fuel pressure that can be recorded and used to compare each injector. Diagnostic Aids * Operating the vehicle over a wide temperature range may help isolate the fuel injector that is causing the condition. * Perform the fuel injector coil test within the conditions of the concern from the customer. A fuel injector condition may only be apparent at a certain temperature, or under certain conditions. Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Special Tools CH 48027-5 - Digital Pressure Gauge For equivalent regional tools, refer to Special Tools (See: Computers and Control Systems/Tools and Equipment). Component Testing Fuel Injector Coil Static Test Verify the resistance of each fuel injector with one of the following methods: * If the engine coolant temperature (ECT) sensor is between 10-32°C (50-90°F), the resistance of each fuel injector should be 11-14 ohm. ‹› If the injectors measure OK, perform the Fuel Injector Balance Test and the Fuel Pressure Test. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Circuit Diagnosis > Page 3060 ‹› If not within the specified range, replace the fuel injector. * If the ECT sensor is not between 10-32°C (50-90°F), measure and record the resistance of each fuel injector with a DMM. Subtract the lowest resistance value from the highest resistance value. The difference between the two should be equal to or less than 3 ohm. ‹› If the difference is equal to or less than 3 ohm, refer to Fuel Pressure Test for further diagnosis of the fuel injectors. ‹› If the difference is more than 3 ohm, add all of the fuel injector resistance values to obtain a total resistance value. Divide the total resistance value by the number of fuel injectors to obtain an average resistance value. Subtract the lowest individual fuel injector resistance value from the average resistance value. Compute the difference between the highest individual fuel injector resistance value and the average resistance value. Replace the fuel injector that displays the greatest difference above or below the average. Fuel Pressure Test Note: * DO NOT perform this test if the engine coolant temperature (ECT) is above 94°C (201°F). Irregular fuel pressure readings may result due to hot soak fuel boiling. * Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic. * Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and Instructions. 1. Install a fuel pressure gauge. Refer to Fuel Pressure Measurement (See: Fuel Pressure/Testing and Inspection/Fuel Pressure Measurement). 2. Turn ON the ignition, with the engine OFF. Note: * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 3. Command the fuel pump relay ON with a scan tool. 4. Observe the fuel pressure gauge with the fuel pump relay commanded ON. The fuel pressure should be 345-414 kPa (50-60 PSI). ‹› If the fuel pressure is not 345-414 kPa (50-60 PSI), refer to Fuel System Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel System Diagnosis). 5. Monitor the fuel pressure gauge for five minutes. The fuel pressure should not decrease more than 34 kPa (5 PSI). ‹› If the fuel pressure decreases more than 34 kPa (5 PSI), refer to Fuel System Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel System Diagnosis). Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Fuel Injector Replacement (See: Service and Repair) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Page 3061 Fuel Injector: Service and Repair Fuel Injector Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair Fuel Line Coupler: Service and Repair Plastic Collar Quick Connect Fitting Service Removal Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). 1. There are several types of plastic collar fuel and evaporative emission quick connect fittings that may be used on this vehicle. * Bartholomew (1) * Q release (2) * Squeeze to release (3) * Sliding retainer (4) * Push down TI (5) Warning: Refer to Safety Glasses and Compressed Air Warning (See: Service Precautions/Technician Safety Information/Safety Glasses and Compressed Air Warning). Note: The following instructions apply to all of these types of fittings except where indicated. 2. Using compressed air, blow any dirt out of the quick connect fitting. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3065 3. This step applies to the Bartholomew style connectors ONLY. Squeeze the plastic quick connect fitting release tabs. 4. This step applies to the Q release type connectors ONLY. Release the fitting by pushing the tab toward the other side of the slot in the fitting. 5. This step applies to the Squeeze to release style connectors ONLY. Squeeze where indicated by arrows on both sides of the plastic ring surrounding the quick connect fitting. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3066 6. This step also applies to the Squeeze to release style connectors ONLY. Squeeze where indicated by the arrows on both sides of the plastic ring surrounding the quick connect fitting. 7. This step applies to the Sliding retainer style connectors ONLY. Release the fitting by pressing on one side of the release tab causing it to push in slightly. If the tab does not move, try pressing the tab in from the opposite side. the tab will only move in one direction. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3067 8. This step applies to the Push down TI style connectors ONLY. Release the fitting by pressing on the tabs indicated by the arrow. Quick Connect Fittings 9. Pull the connection apart. 10. Wipe off the male pipe end using a clean shop towel. 11. Inspect both ends of the fitting for dirt and burrs. 12. Clean or replace the components as required. Installation Procedure 1. Apply a few drops of clean engine oil to the male connection end. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3068 2. Push both sides of the quick connect fitting together in order to cause the retaining feature to snap into place. 3. Once installed, pull on both sides of the quick connect fitting in order to make sure the connection is secure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair Fuel Pressure Sensor/Switch: Service and Repair Fuel Pressure Sensor Replacement Removal Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Warning: Refer to Safety Goggles and Fuel Warning (See: Service Precautions/Safety Goggles and Fuel Warning). 1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the fuel pressure sensor wiring harness plug (2) from the fuel pressure sensor (1). 4. Remove the fuel pressure sensor (1) from the fuel pressure relief valve (2). 5. Remove the fuel pressure sensor seal ring (3). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Page 3072 Installation Procedure 1. Install a NEW fuel pressure sensor seal ring (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the fuel pressure sensor (1) to the fuel pressure relief valve (2) and tighten to 19 Nm (14 lb ft). 3. Plug the fuel pressure sensor wiring harness plug (2) to the fuel pressure sensor (1). 4. Lower the vehicle. 5. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURE Fuel Pressure (Key ON, Engine OFF).................................................................................................. .............................................250-450 kPa (36-65 PSI) Should not decrease greater than........................................................................................................ .................................................34 kPa (5 PSI) in 1 min Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3077 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description When the ignition is turned ON, the engine control module (ECM) supplies power to the in-tank fuel pump, by energizing the fuel pump relay. The in-tank fuel pump remains ON as long as the engine is cranking or running and the ECM receives crankshaft reference pulses. If there are no reference pulses, the ECM turns the in-tank fuel pump OFF, 2 s after the ignition switch is turned ON or 2 s after the engine stops running. The electric fuel pump is incorporated into the modular fuel pump and sender assembly and is located inside the fuel tank. The fuel pump supplies fuel through a fuel filter, also located in the modular fuel pump and sender assembly, through the fuel feed pipes, to the fuel rail assembly. The fuel pump provides fuel at a pressure above the pressure needed by the fuel injectors. The fuel pressure regulator, located in the modular fuel pump and sender assembly, keeps the fuel available to the fuel injectors at a regulated pressure. When the fuel pressure rises above the pressure regulator calibration, the pressure is relieved, with excess fuel exhausted into the modular fuel pump and sender assembly reservoir. Reference Information Description and Operation Fuel System Description (See: Computers and Control Systems/Description and Operation/Fuel System Description) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Special Tools * CH 48027 - Digital Pressure Gauge * EN 37287 - Fuel Line Shut-Off Adapters For equivalent regional tools, refer to Special Tools (See: Computers and Control Systems/Tools and Equipment). Circuit/System Verification Note: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that an adequate amount of fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. 1. Ignition ON, command the KR23A Fuel Pump Relay ON with a scan tool. You should hear the G12 Fuel Pump turn ON and OFF. ‹› If the G12 Fuel Pump does not turn ON, refer to Fuel Pump Electrical Circuit Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Pump Electrical Circuit Diagnosis). 2. Ignition OFF, all accessories OFF, install the CH 48027 - Digital Pressure Gauge. 3. Ignition ON, command the KR23A Fuel Pump Relay ON with a scan tool. Verify the fuel pressure is between 250-450 kPa (36-65 PSI) and remains steady for 5 m. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 3080 Circuit/System Testing Note: * The KR23A Fuel Pump Relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Do not start the engine. 1. Ignition ON, engine OFF, command the KR23A Fuel Pump Relay ON with a scan tool and observe the fuel pressure gauge while the G12 Fuel Pump is operating. Verify the fuel pressure is between 250-450 kPa (36-65 PSI). ‹› If the fuel pressure is greater than the specified range, replace the G12 Fuel Pump. ‹› If the fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all items test normal, replace the G12 Fuel Pump. * Restricted fuel feed pipe * Restricted or clogged strainer * Restricted or plugged fuel filter * Inspect the G12 Fuel Pump harness connectors and the ground circuits of the fuel pump for poor connections. Note: The fuel pressure may vary slightly when the G12 Fuel Pump stops operating. After the G12 Fuel Pump stops operating, the fuel pressure should stabilize and remain constant. 2. Verify the fuel pressure does not decrease greater than 34 kPa (5 PSI) in 1 min. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve fuel pressure. 2. Install the EN 37287 - Fuel Line Shut-Off Adapters between the fuel feed pipe and the fuel rail. 3. Open the valve on the EN 37287 - Fuel Line Shut-Off Adapters. 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the digital pressure gauge. 5. Close the valve on the EN 37287 - Fuel Line Shut-Off Adapters. 6. Verify the fuel pressure does not decrease greater than 34 kPa (5 PSI) in 1 minute. ‹› If the fuel pressure decreases more than 34 kPa (5 PSI) within the specified time, locate and replace the leaking fuel injector(s). ‹› If the fuel pressure does not decrease more than 34 kPa (5 PSI) within the specified time, replace the G12 Fuel Pump. 3. Relieve the fuel pressure to 69 kPa (10 PSI). Verify that the fuel pressure does not decrease more than 14 kPa (2 PSI) in 5 min. ‹› If the fuel pressure decreases more than the specified value, replace the G12 Fuel Pump. 4. Remove the EN 37287 - Fuel Line Shut-Off Adapters and CH 48027 - Digital Pressure Gauge. 5. Operate the vehicle within the conditions of the customers concern while monitoring fuel related parameters with a scan tool. The scan tool parameters should not indicate a lean condition. ‹› If the scan tool parameters indicate a lean condition, test for a restricted fuel feed pipe, restricted fuel filter, or poor connections at the harness connectors and ground circuits of the fuel pump. If all test normal, replace the fuel pump. 6. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls). Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 3081 Fuel Pressure: Testing and Inspection Fuel Pressure Measurement Fuel Pressure Measurement Special Tools EN-34730-91 - Pressure Tester For equivalent regional tools, refer to Special Tools (See: Computers and Control Systems/Tools and Equipment) Warning Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Remove the protective cap from the test connection. 2. Attach the EN-34730-91 - tester (1) to the test connection. 3. Start the engine. * Bleed the pressure tester at idling speed. * Collect the exiting fuel in a suitable container. * Read the fuel pressure from the pressure gauge. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 4. Detach the pressure gauge EN-34730-91 - tester from the test connection. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3085 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3086 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3087 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair Fuel Rail: Service and Repair Fuel Injection Fuel Rail Assembly Replacement Removal Procedure 1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Remove engine sight shield. 3. Remove the fuel feed pipe from fuel injection fuel rail. Refer to Fuel Feed Pipe Replacement (See: Fuel Supply Line/Service and Repair). 4. Remove the positive crankcase ventilation pipe from the intake manifold. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement ( See: Emission Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair). 5. Disconnect the 4 fuel injector wiring harness plugs (2). 6. Unclip the ECM wiring harness from retainer clips (1) and the camshaft cover. 7. Remove the ground cable nut (2) and the ground cable. 8. Remove the 2 fuel injection fuel rail bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Page 3091 9. Remove the fuel injection fuel rail assembly (1) and the 4 fuel injector seal rings (2). Installation Procedure Note: Lubricate the 4 fuel injector seal rings (2) with clean engine oil. 1. Install the fuel injection fuel rail assembly (1) to the intake manifold. Use NEW fuel injector seal rings (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Page 3092 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 2 fuel injection fuel rail bolts (1) and tighten to 7 Nm (62 lb in). 3. Install the ground cable and the ground cable nut (2) and tighten. 4. Connect the 4 fuel injector wiring harness plugs (2). 5. Clip the ECM wiring harness to the retainer clip (1) and the camshaft cover. 6. Install the positive crankcase ventilation pipe to the intake manifold. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (See: Emission Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair). 7. Install the fuel feed pipe to the fuel injection fuel rail. Refer to Fuel Feed Pipe Replacement (See: Fuel Supply Line/Service and Repair). 8. Install the engine sight shield. 9. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair Fuel Supply Line: Service and Repair Fuel Feed Pipe Replacement Removal Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). 1. Open the hood. 2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Relieve the fuel pressure. Refer to Fuel Pressure Relief (See: Fuel Filter/Fuel Pressure Release/Service and Repair). 4. Disconnect the fuel feed pipe connector (3) from fuel injector rail. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair). 5. Unclip the fuel feed pipe (1) from the retainer clip (4). 6. Close the fuel feed pipe connector with a suitable cap. 7. Unclip the fuel feed pipe from the bulk head retainer clip (2). 8. Remove the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement (See: Body and Frame/Frame/Subframe/Front Subframe/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Page 3096 9. Open the 4 fuel pipe clips (2). 10. Remove the fuel feed pipe (1) from lower bulkhead and underbody. 11. Disconnect the fuel tank feed pipe connector (1) from the fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair). 12. Close the fuel feed pipe and fuel tank feed pipe with suitable caps. 13. Disconnect the fuel pressure sensor wiring harness plug (2). 14. Open the rear fuel pipe clip and remove the fuel feed pipe. Installation Procedure 1. Remove the caps from fuel feed tank pipe and fuel feed pipe. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Page 3097 2. Install the fuel feed pipe and secure with the rear fuel pipe clip. 3. Connect the fuel tank feed pipe connector (1) to the fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair). 4. Connect the fuel pressure sensor wiring harness plug (2). 5. Install the fuel feed pipe (1) to lower bulkhead and underbody. 6. Close the 4 fuel pipe clips (2). 7. Install the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement (See: Body and Frame/Frame/Subframe/Front Subframe/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Page 3098 8. Clip the fuel feed pipe to the bulk head retainer clip (2). 9. Clip the fuel feed pipe (1) to the retainer clip (4). 10. Connect the fuel feed pipe connector (3) to the fuel injector rail. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair). 11. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 12. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair Fuel Filler Hose: Service and Repair Fuel Tank Filler Pipe Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Service and Repair Fuel Filler Neck: Service and Repair Fuel Tank Filler Pipe Housing Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair Fuel Gauge Sender: Service and Repair Fuel Sender Assembly Replacement Removal Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Warning: Refer to Safety Goggles and Fuel Warning (See: Service Precautions/Safety Goggles and Fuel Warning). Caution: Use care while handling the fuel sender to prevent damage and incorrect fuel level readings. 1. Remove the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Pump/Service and Repair/Fuel Tank Fuel Pump Module Replacement). 2. Disconnect the fuel sender assembly wiring harness plugs (1). 3. Unclip the 2 fuel sender retainer pins. 4. Remove the fuel sender assembly (2). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Page 3109 1. Install the fuel sender assembly (2). 2. Connect the fuel sender assembly wiring harness plugs (1). 3. Install the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Pump/Service and Repair/Fuel Tank Fuel Pump Module Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair Fuel Tank Unit: Service and Repair Fuel Sender Assembly Replacement Removal Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Warning: Refer to Safety Goggles and Fuel Warning (See: Service Precautions/Safety Goggles and Fuel Warning). Caution: Use care while handling the fuel sender to prevent damage and incorrect fuel level readings. 1. Remove the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Pump/Service and Repair/Fuel Tank Fuel Pump Module Replacement). 2. Disconnect the fuel sender assembly wiring harness plugs (1). 3. Unclip the 2 fuel sender retainer pins. 4. Remove the fuel sender assembly (2). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Page 3113 1. Install the fuel sender assembly (2). 2. Connect the fuel sender assembly wiring harness plugs (1). 3. Install the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Pump/Service and Repair/Fuel Tank Fuel Pump Module Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood Main Relay (Computer/Fuel System): Locations Fuse Block - Underhood Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 3118 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 3119 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 3120 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 3121 Main Relay (Computer/Fuel System): Locations Fuse Block - Instrument Panel Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block - Underhood > Page 3122 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations Oil Pressure Switch (For Fuel Pump): Locations Disassembled Views Cylinder Head Assembly 1 - Camshaft Cover 2 - Oil Level Indicator 3 - Camshaft Cover Bolt 4 - Oil Filler Cap 5 - Oil Filler Cap Seal Ring 6 - Camshaft Cover Gasket 7 - Camshaft Bearing Cap Bolt 8 - Camshaft Bearing Cap 9 - Cylinder Head Bolt 10 - Valve Keys 11 - Valve Spring Retainer 12 - Valve Spring 13 Engine Lift Bracket Left Side 14 - Engine Lift Bracket Bolt 15 - Cylinder Head 16 - Intake Valve Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 3126 17 - Exhaust Valve 18 - Engine Lift Bracket 19 - Engine Lift Bracket Bolt 20 - Engine Lift Bracket 21 - Engine Lift Bracket Bolt 22 - Oil Pressure Indicator Switch 23 - Oil Pressure Indicator Switch Seal Ring 24 - Hydraulic Valve Lash Adjuster 25 - Hydraulic Valve Lash Adjuster Arm 26 - Exhaust Camshaft 27 - Intake Camshaft Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 3127 Oil Pressure Switch (For Fuel Pump): Service and Repair Engine Oil Pressure Indicator Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3132 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3133 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3134 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block Underhood Main Relay (Computer/Fuel System): Locations Fuse Block - Underhood Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block Underhood > Page 3139 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block Underhood > Page 3140 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block Underhood > Page 3141 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block Underhood > Page 3142 Main Relay (Computer/Fuel System): Locations Fuse Block - Instrument Panel Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Fuse Block Underhood > Page 3143 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3148 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views B107 Accelerator Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3149 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Right Front of the Vehicle Components 1 of 2 1 - B75B Mass Air Flow/Intake Air Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3153 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor Replacement (1.4L LUH and LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair Fuel Pressure Sensor/Switch: Service and Repair Fuel Pressure Sensor Replacement Removal Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Warning: Refer to Safety Goggles and Fuel Warning (See: Service Precautions/Safety Goggles and Fuel Warning). 1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the fuel pressure sensor wiring harness plug (2) from the fuel pressure sensor (1). 4. Remove the fuel pressure sensor (1) from the fuel pressure relief valve (2). 5. Remove the fuel pressure sensor seal ring (3). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Page 3157 Installation Procedure 1. Install a NEW fuel pressure sensor seal ring (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the fuel pressure sensor (1) to the fuel pressure relief valve (2) and tighten to 19 Nm (14 lb ft). 3. Plug the fuel pressure sensor wiring harness plug (2) to the fuel pressure sensor (1). 4. Lower the vehicle. 5. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations Oil Pressure Switch (For Fuel Pump): Locations Disassembled Views Cylinder Head Assembly 1 - Camshaft Cover 2 - Oil Level Indicator 3 - Camshaft Cover Bolt 4 - Oil Filler Cap 5 - Oil Filler Cap Seal Ring 6 - Camshaft Cover Gasket 7 - Camshaft Bearing Cap Bolt 8 - Camshaft Bearing Cap 9 - Cylinder Head Bolt 10 - Valve Keys 11 - Valve Spring Retainer 12 - Valve Spring 13 Engine Lift Bracket Left Side 14 - Engine Lift Bracket Bolt 15 - Cylinder Head 16 - Intake Valve Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 3161 17 - Exhaust Valve 18 - Engine Lift Bracket 19 - Engine Lift Bracket Bolt 20 - Engine Lift Bracket 21 - Engine Lift Bracket Bolt 22 - Oil Pressure Indicator Switch 23 - Oil Pressure Indicator Switch Seal Ring 24 - Hydraulic Valve Lash Adjuster 25 - Hydraulic Valve Lash Adjuster Arm 26 - Exhaust Camshaft 27 - Intake Camshaft Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 3162 Oil Pressure Switch (For Fuel Pump): Service and Repair Engine Oil Pressure Indicator Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations Turbo Boost Sensor: Locations Powertrain Component Views Engine Components - Left Rear (LUJ) 1 - B111 Turbocharger Boost Pressure Sensor 2 - T8 Ignition Coil 3 - B68 Knock Sensor (KS) 4 Q38 Throttle Body 5 - B34 Engine Coolant Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Procedures Throttle Body: Procedures Throttle Body Inspection and Cleaning Note: Over extended time and mileage, deposits may accumulate on the back of the throttle valve plate. The source of the deposit is exhaust gas. Typically these deposits pose no problem. Occasionally the deposit may accumulate to a point where perceived pedal effort or throttle valve movement is effected. This procedure should not be performed on vehicles with mileage under 80,450 km (50,000 mi). 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (1.4L LUH and LUJ) (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Warning Turn OFF the ignition before inserting fingers into the throttle bore. Unexpected movement of the throttle blade could cause personal injury. Caution: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate. 2. Inspect the throttle body bore and the throttle valve plate for deposits. You will need to open the throttle valve in order to inspect all surfaces. Caution: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components. 3. Clean the throttle body bore and the throttle valve plate using a clean shop towel with an appropriate cleaner. 4. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (1.4L LUH and LUJ) (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Procedures > Page 3170 Throttle Body: Removal and Replacement Throttle Body Assembly Replacement (1.4L LUH and LUJ) Removal Procedure 1. Open the hood. 2. Disconnect the throttle body wiring harness plug (1). 3. Remove the charge air cooler outlet air hose from the throttle body. Refer to Charge Air Cooler Outlet Air Hose Replacement (See: Turbocharger/Intercooler/Intercooler Duct/Service and Repair). 4. Remove the 4 throttle body bolts (3). 5. Remove the throttle body (2) along with the throttle body seal ring (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Procedures > Page 3171 1. Install the throttle body (2) along with a NEW throttle body seal ring (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 4 throttle body bolts (3) and tighten to 8 Nm (71 lb in). 3. Install the charge air cooler outlet air hose to the throttle body. Refer to Charge Air Cooler Outlet Air Hose Replacement (See: Turbocharger/Intercooler/Intercooler Duct/Service and Repair). 4. Connect the throttle body wiring harness plug (1). 5. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Intercooler Duct > Component Information > Service and Repair Intercooler Duct: Service and Repair Charge Air Cooler Outlet Air Hose Replacement Removal Procedure 1. Open the hood. 2. Disconnect the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Disconnect the turbocharger pressure sensor wiring harness plug (1). 4. Loosen the charge air cooler outlet air hose clamp (2). 5. Remove the charge air cooler outlet air hose (3) from the throttle body. 6. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 7. Remove the charger air cooler outlet air hose bolt (3). 8. Loosen the clamp. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Intercooler Duct > Component Information > Service and Repair > Page 3177 9. Remove the charger air cooler outlet air hose (1) from the charge air cooler (2). Installation Procedure 1. Install the charger air cooler outlet air hose (1) to the charge air cooler (2). 2. Install the clamp. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the charger air cooler outlet air hose bolt (3) and tighten to 8 Nm (71 lb in). 4. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 5. Install the charger air cooler outlet air hose (3) to the throttle body. 6. Install and tighten the charger air cooler outlet air hose clamp (2). 7. Connect the turbocharger pressure sensor wiring harness plug (1). 8. Connect the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 9. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Locations Turbo Boost Sensor: Locations Powertrain Component Views Engine Components - Left Rear (LUJ) 1 - B111 Turbocharger Boost Pressure Sensor 2 - T8 Ignition Coil 3 - B68 Knock Sensor (KS) 4 Q38 Throttle Body 5 - B34 Engine Coolant Temperature Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Coolant Line > Component Information > Service and Repair > Turbocharger Coolant Feed Pipe Replacement Turbocharger Coolant Line: Service and Repair Turbocharger Coolant Feed Pipe Replacement Turbocharger Coolant Feed Pipe Replacement (1.4L LUH and LUJ) Removal Procedure 1. Remove the turbocharger. Refer to Turbocharger Replacement (See: Service and Repair). 2. Remove the turbocharger coolant feed pipe from quick fitting connector. Refer to Turbocharger Disassemble (See: Engine, Cooling and Exhaust/Engine/Service and Repair/Overhaul/54. Turbocharger Disassemble). Installation Procedure 1. Install the turbocharger coolant feed pipe to the quick fitting connector. Refer to Turbocharger Assemble (See: Engine, Cooling and Exhaust/Engine/Service and Repair/Overhaul/56. Turbocharger Assemble). 2. Install the turbocharger. Refer to Turbocharger Replacement (See: Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Coolant Line > Component Information > Service and Repair > Turbocharger Coolant Feed Pipe Replacement > Page 3185 Turbocharger Coolant Line: Service and Repair Turbocharger Coolant Return Pipe Replacement Turbocharger Coolant Return Pipe Replacement (1.4L LUH and LUJ) Removal Procedure 1. Remove the turbocharger. Refer to Turbocharger Replacement (See: Service and Repair). 2. Remove the turbocharger coolant return pipe from quick fitting connector. Refer to Turbocharger Disassemble (See: Engine, Cooling and Exhaust/Engine/Service and Repair/Overhaul/54. Turbocharger Disassemble). 3. Replace the quick fitting connector. Refer to Turbocharger Disassemble (See: Engine, Cooling and Exhaust/Engine/Service and Repair/Overhaul/54. Turbocharger Disassemble). Installation Procedure 1. Install the turbocharger coolant return pipe to the quick fitting connector. Refer to Turbocharger Disassemble (See: Engine, Cooling and Exhaust/Engine/Service and Repair/Overhaul/54. Turbocharger Disassemble). 2. Install the turbocharger. Refer to Turbocharger Replacement (See: Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Oil Line, Turbocharger > Component Information > Service and Repair > Turbocharger Oil Feed Pipe Replacement Oil Line: Service and Repair Turbocharger Oil Feed Pipe Replacement Turbocharger Oil Feed Pipe Replacement Removal Procedure 1. Open the hood. 2. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (1.4L LUH and LUJ) (See: Engine, Cooling and Exhaust/Exhaust System/Heat Shield/Service and Repair/Exhaust Manifold Heat Shield Replacement)Exhaust Manifold Heat Shield Replacement (1.6L LDE, LXV, 1.8L 2H0, and LUW) (See: Engine, Cooling and Exhaust/Exhaust System/Heat Shield/Service and Repair/Exhaust Manifold Heat Shield Replacement). 4. Remove the turbocharger oil feed pipe bolt (5). 5. Remove the turbocharger oil feed pipe hollow screw (4) and the 2 seal rings (1) and (3). 6. Remove the turbocharger oil feed pipe (2) and the rubber seal ring. Installation Procedure 1. Clean the sealing surfaces. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Oil Line, Turbocharger > Component Information > Service and Repair > Turbocharger Oil Feed Pipe Replacement > Page 3190 2. Install the turbocharger oil feed pipe (2) along with a NEW rubber seal ring. 3. Install the turbocharger oil feed pipe hollow screw (4) and 2 NEW seal rings (1) and (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the turbocharger oil feed pipe bolt (5) and tighten to 10 Nm (89 lb in). 5. Tighten the turbocharger oil feed pipe hollow screw to 30 Nm (22 lb ft). 6. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (1.4L LUH and LUJ) (See: Engine, Cooling and Exhaust/Exhaust System/Heat Shield/Service and Repair/Exhaust Manifold Heat Shield Replacement)Exhaust Manifold Heat Shield Replacement (1.6L LDE, LXV, 1.8L 2H0, and LUW) (See: Engine, Cooling and Exhaust/Exhaust System/Heat Shield/Service and Repair/Exhaust Manifold Heat Shield Replacement). 7. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 8. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Oil Line, Turbocharger > Component Information > Service and Repair > Turbocharger Oil Feed Pipe Replacement > Page 3191 Oil Line: Service and Repair Turbocharger Oil Return Pipe Replacement Turbocharger Oil Return Pipe Replacement Removal procedure 1. Open the hood. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) Note: Simplified Graphic. DO NOT remove the warm up three way catalytic converter. 3. Remove the 2 turbocharger oil return pipe bolts (1). 4. Place a drain pan below the vehicle. 5. Release the turbocharger oil return pipe connector (4) and disconnect the turbocharger oil return pipe from the engine block. 6. Remove the turbocharger oil return pipe (2) and the gasket (3). Installation Procedure 1. Clean the sealing surfaces. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Oil Line, Turbocharger > Component Information > Service and Repair > Turbocharger Oil Feed Pipe Replacement > Page 3192 2. Install the turbocharger oil return pipe (2) in compound with a NEW gasket (3) and connect to the engine block. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 2 turbocharger oil return pipe bolts (1) and tighten to 8 Nm (71 lb in). 4. Lower the vehicle. 5. Check engine oil level. 6. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications Ignition System Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle Camshaft Position Sensor: Customer Interest Engine - Lack of Power with Multiple DTCs or Rattle TECHNICAL Bulletin No.: 10-06-04-016 Date: December 20, 2010 Subject: Engine Lack of Power with DTCs P0011, P0014, P000A, P000B, P0012, P0015 or Engine Rattle Noise (Remove Oil Filters from Intake and Exhaust Camshaft Position Actuator Solenoid Valves) Models: 2008-2011 Chevrolet Aveo 2011 Chevrolet Cruze (US and Canada) 2009-2011 Chevrolet Cruze (Export Only) 2008-2009 Pontiac G3, Wave 2008-2009 Saturn Astra Condition Some customers may comment on lack of power with the following DTCs or an engine rattle noise from the sprockets. Cruze GEN3 1.6/1.8D - P0011: Intake Camshaft Position (CMP) System Performance - P0014: Exhaust Camshaft Position (CMP) System Performance - P000A: Intake Camshaft Position System Slow Response - P000B: Exhaust Camshaft Position System Slow Response Aveo GEN3 1.4D - P0012: Intake Camshaft Position (CMP) System Performance Bank 1-Retarded - P0015: Exhaust Camshaft Position (CMP) System Performance Bank 1-Retarded Aveo/G3/Wave Gen3 1.6D - P0011: Intake Camshaft Position (CMP) System Performance Bank 1 - P0014: Exhaust Camshaft Position (CMP) System Performance Bank 1 Correction Remove four oil filters from the intake and exhaust camshaft position actuator solenoid valves. 1. Open the hood. 2. Disconnect the negative battery cable. 3. Disconnect the camshaft position actuator solenoid valve connectors. 4. Remove the power steering line bracket bolt and reposition the bracket (for 1.6/1.8L only). 5. Disconnect PCV pipe and reposition (for 1.6/1.8L only). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 3205 6. Remove the camshaft position actuator solenoid valve bolts. 7. Remove the camshaft position actuator solenoid valves and seals. 8. Check whether the filter is broken or not (1). 9. Remove the four filters (intake and exhaust). 1. Broken Filter: Remove filter with a blunt tool. 2. Unbroken Filter 1. Locate the filter hinge between the holes. 2. Cut the filter hinge slightly. Caution Do not scratch the valve surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 3206 3. Remove the filter with a blunt tool. 10. Install the camshaft position actuator solenoid valves and seals. Coat the seal with clean engine oil prior to installation. 11. Install the camshaft position actuator solenoid valve bolts. Tighten Tighten the bolts to 6 Nm (53 lb in). 12. Connect the camshaft position actuator solenoid valve connectors. 13. Reposition and install the PCV pipe (for 1.6/1.8 only). 14. Reposition the power steering bracket and install the power steering line bracket bolt (for 1.6/1.8 only). 15. Connect the negative battery cable. Note If an engine rattle noise is heard after removing the filters, refer to SI for further diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle Camshaft Position Sensor: All Technical Service Bulletins Engine - Lack of Power with Multiple DTCs or Rattle TECHNICAL Bulletin No.: 10-06-04-016 Date: December 20, 2010 Subject: Engine Lack of Power with DTCs P0011, P0014, P000A, P000B, P0012, P0015 or Engine Rattle Noise (Remove Oil Filters from Intake and Exhaust Camshaft Position Actuator Solenoid Valves) Models: 2008-2011 Chevrolet Aveo 2011 Chevrolet Cruze (US and Canada) 2009-2011 Chevrolet Cruze (Export Only) 2008-2009 Pontiac G3, Wave 2008-2009 Saturn Astra Condition Some customers may comment on lack of power with the following DTCs or an engine rattle noise from the sprockets. Cruze GEN3 1.6/1.8D - P0011: Intake Camshaft Position (CMP) System Performance - P0014: Exhaust Camshaft Position (CMP) System Performance - P000A: Intake Camshaft Position System Slow Response - P000B: Exhaust Camshaft Position System Slow Response Aveo GEN3 1.4D - P0012: Intake Camshaft Position (CMP) System Performance Bank 1-Retarded - P0015: Exhaust Camshaft Position (CMP) System Performance Bank 1-Retarded Aveo/G3/Wave Gen3 1.6D - P0011: Intake Camshaft Position (CMP) System Performance Bank 1 - P0014: Exhaust Camshaft Position (CMP) System Performance Bank 1 Correction Remove four oil filters from the intake and exhaust camshaft position actuator solenoid valves. 1. Open the hood. 2. Disconnect the negative battery cable. 3. Disconnect the camshaft position actuator solenoid valve connectors. 4. Remove the power steering line bracket bolt and reposition the bracket (for 1.6/1.8L only). 5. Disconnect PCV pipe and reposition (for 1.6/1.8L only). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 3212 6. Remove the camshaft position actuator solenoid valve bolts. 7. Remove the camshaft position actuator solenoid valves and seals. 8. Check whether the filter is broken or not (1). 9. Remove the four filters (intake and exhaust). 1. Broken Filter: Remove filter with a blunt tool. 2. Unbroken Filter 1. Locate the filter hinge between the holes. 2. Cut the filter hinge slightly. Caution Do not scratch the valve surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 3213 3. Remove the filter with a blunt tool. 10. Install the camshaft position actuator solenoid valves and seals. Coat the seal with clean engine oil prior to installation. 11. Install the camshaft position actuator solenoid valve bolts. Tighten Tighten the bolts to 6 Nm (53 lb in). 12. Connect the camshaft position actuator solenoid valve connectors. 13. Reposition and install the PCV pipe (for 1.6/1.8 only). 14. Reposition the power steering bracket and install the power steering line bracket bolt (for 1.6/1.8 only). 15. Connect the negative battery cable. Note If an engine rattle noise is heard after removing the filters, refer to SI for further diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3219 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3220 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3221 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 3226 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3231 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3232 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3233 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 3238 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3243 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3244 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3245 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3251 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3252 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 3253 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 3258 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3263 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3264 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3265 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 3270 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3275 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3276 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 3277 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Disassembled Views Camshaft Position Sensor: Locations Disassembled Views Disassembled Views Engine Front Cover And Oil Pump Assembly (1 of 2) 1 - Camshaft Position Actuator Solenoid Valve Bolt 2 - Intake Camshaft Position Actuator Solenoid Valve 3 - Exhaust Camshaft Position Actuator Solenoid Valve 4 - Intake Camshaft Position Sensor Bolt 5 - Intake Camshaft Position Sensor 6 - Intake Camshaft Position Sensor Seal Ring 7 - Engine Front Cover 8 - Engine Front Cover Gasket 9 - Exhaust Camshaft Position Sensor Seal Ring 10 Exhaust Camshaft Position Sensor 11 - Exhaust Camshaft Position Sensor Bolt 12 - Engine Front Cover Oil Gallery Plug 13 - Engine Front Cover Oil Gallery Plug Seal Ring 14 - Oil Pressure Relief Valve Piston 15 - Oil Pressure Relief Valve Spring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 3280 16 - Oil Pressure Relief Valve Plug 17 - Engine Front Cover Bolt (M10) 18 - Crankshaft Front Oil Seal 19 - Engine Front Cover Bolt (M6) 20 - Water Drain Plug Seal Ring 21 - Water Drain Plug 22 Exhaust Camshaft Position Actuator Solenoid Valve Bolt Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 3281 Camshaft Position Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Front (LUJ) 1 - Q6E Camshaft Position Actuator Solenoid Valve - Exhaust 2 - B23E Camshaft Position Sensor Exhaust 3 - B37 Engine Oil Pressure Switch 4 - B52A Heated Oxygen Sensor 1 5 - Q42 Turbocharger Wastegate Solenoid Valve 6 - Q2 A/C Compressor Clutch Engine Components - Right Rear (LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 3282 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3283 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Open hood. Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 2. Disconnect the camshaft position sensor wiring harness plug (1). Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 3. Remove the camshaft position sensor bolt (3). 4. Remove the camshaft position sensor (2) and the seal ring (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3284 Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 1. Install the camshaft position sensor (2) and the seal ring (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 2. Install the camshaft position sensor bolt (3) and tighten to 8 Nm (71 lb in). Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 3. Connect the camshaft position sensor wiring harness plug (1). 4. After replacement of an camshaft position sensor, use a scan tool to speed up learn function. Refer to Engine Control Module Programming and Setup (LUW, LUJ) (See: Testing and Inspection/Programming and Relearning/Engine Control Module Programming and Setup) 5. Close hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views Crankshaft Position Sensor: Locations Disassembled Views Disassembled Views Engine Block Assembly - 1.4L LDD 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Engine Block 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 3289 16 - Oil Pan Bolt 17 - Oil Pan Drain Plug Seal Ring 18 - Oil Pan Drain Plug 19 - Crankshaft Position Sensor Bolt 20 - Crankshaft Position Sensor 21 - Crankshaft Position Sensor Seal Ring 22 Crankshaft Bearing Cap Tie Plate Bolt (M8) 23 - Crankshaft Position Sensor Reluctor Ring 24 Flywheel Bolt 25 - Engine Flywheel 26 - Crankshaft Rear Oil Seal 27 - Crankshaft Position Sensor Reluctor Ring Bolt 28 - Connecting Rod Bearing Cap Bolt 29 - Connecting Rod Bearing Cap 30 Lower Connecting Rod Bearing 31 - Upper Connecting Rod Bearing 32 - Connecting Rod 33 Piston Pin 34 - Piston 35 - Piston Oil Ring (With oil Ring Spacer) 36 - Lower Compression Ring 37 - Upper Compression Ring Engine Block Assembly - 1.4L LUH and LUJ Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 3290 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Cylinder Head 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Baffle 16 - Oil Pan Baffle Bolt 17 - Oil Pan 18 - Oil Pan Bolt 19 - Oil Pan Drain Plug 20 - Crankshaft Position Sensor Bolt 21 - Crankshaft Position Sensor 22 - Crankshaft Position Sensor Seal Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 3291 23 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 24 - Piston Oil Nozzle 25 - Crankshaft Position Sensor Reluctor Ring 26 - Crankshaft Position Sensor Reluctor Ring Bolt 27 - Crankshaft Rear Oil Seal 28 - Engine Flywheel (Two-Mass) 29 - Engine Flywheel Bolt 30 - Connecting Rod Bearing Cap Bolt 31 - Connecting Rod Bearing Cap 32 - Lower Connecting Rod Bearing 33 - Upper Connecting Rod Bearing 34 - Connecting Rod 35 - Piston Pin 36 - Piston Pin Retainer 37 - Piston Pin Retainer 38 - Piston 39 - Piston Oil Ring (With Oil Ring Spacer) 40 - Lower Compression Ring 41 - Upper Compression Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 3292 Crankshaft Position Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Rear (LUJ) 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3293 Crankshaft Position Sensor: Diagrams Component Connector End Views B26 Crankshaft Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3294 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The crankshaft position sensor system variation learn procedure is required when the following service procedures have been performed, regardless of whether DTC P0315 00 is set: * Engine replacement * Engine control module (ECM) replacement * Crankshaft damper replacement * Crankshaft replacement * Crankshaft Position Sensor Replacement * Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Note: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the crankshaft position sensor system variation learn procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * Crankshaft Position Sensor activity - If there is a crankshaft position sensor condition, refer to the applicable DTC that set. * Camshaft position signal activity - If there is a camshaft position sensor signal condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT) - If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P0315 00, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select the Crankshaft Position System Variation Learn procedure and perform the following: 1. Observe the fuel cut-off for the applicable engine. 2. Block the drive wheels. 3. Set the parking brake. 4. Place the vehicles transmission in Park or Neutral. 5. Turn the air conditioning (A/C) OFF. 6. Cycle the ignition from OFF to ON. 7. Apply and hold the brake pedal for the duration of the procedure. 8. Start and idle the engine. 9. Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 10. Release the throttle when fuel cut-off occurs. ‹› Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC P0315 00 ran and passed, the crankshaft position sensor variation learn procedure is complete. If the scan tool indicates DTC P0315 00 failed or did not run, refer to DTC P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 5. Turn OFF the ignition for 30 s after the learn procedure is completed successfully. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3295 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection Ignition Coil: Testing and Inspection Electronic Ignition System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description This ignition system uses individual Ignition Coil assemblies for each cylinder. The engine control module (ECM) controls the spark events by transmitting the timing pulses on the ignition control circuits to the individual ignition coil assemblies in firing order sequence. Each ignition coil has the following circuits: * An ignition voltage circuit * A ground circuit * An ignition control circuit Diagnostic Aids * This test procedure requires that the vehicle battery has passed a load test and is completely charged. * There is an adequate supply of fuel in the fuel tank. * When disconnecting electrical connectors or removing fuses and relays from a fuse block, always inspect both mating electrical terminals for corrosion and terminal tightness. * Use the EL 35616-E - terminal test kit for any test that requires probing the underhood fuse block terminals, component wire harness terminals, or the ECM wire harness terminals. * A slight to moderate resistance in the ignition voltage circuit can cause a misfire condition or a crank/no start concern. * Extended engine cranking time, will foul the spark plugs with excessive fuel and cause a crank/no start condition. Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Description and Operation Electronic Ignition System Description (See: Computers and Control Systems/Description and Operation/Electronic Ignition System Description) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Special Tools * EL 26792 - HEI Spark Tester * EL 35616-E - Terminal Test Kit For equivalent regional tools, refer to Special Tools (See: Computers and Control Systems/Tools and Equipment). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Page 3299 Circuit/System Verification Note: Verify that the engine is in good mechanical condition before continuing with this diagnostic. Observe the engine controls schematic for the ignition module/coils, and review the ignition system specifications to verify the following concerns: * The ignition modules/coils are correctly wired and connected. * The proper spark plug type, refer to Spark Plug Inspection (See: Spark Plug/Testing and Inspection). * The proper spark plug gap and torque. * The proper ohm values for the spark plug wires. Circuit/System Testing 1. Turn OFF the ignition. Note: If the ignition fuse F9 is open, it will be necessary to test the spliced ignition circuits and the components for a short to ground. 2. Inspect the fuse that supplies ignition voltage to the ignition module/coils. ‹› If fuse F9 is open, test all ignition voltage circuits to the T8 Ignition Coil for a short to ground. 3. Disconnect the T8 Ignition Coil connector. 4. Replace the open fuse F9 with a new fuse. 5. Ignition ON, engine OFF. 6. Reconnect T8 Ignition Coil connector. ‹› If the fuse F9 opens when connecting the T8 Ignition Coil, then replace the T8 Ignition Coil. 7. Ignition OFF, disconnect the T8 Ignition Coil electrical connector. 8. Ignition ON, verify that a test lamp illuminates between the ignition voltage circuit terminal A and ground. ‹› If the test lamp does not illuminate test the T8 Ignition Coil Ignition Voltage Circuit for an open/high resistance. 9. Verify that a test lamp illuminates between the T8 Ignition Coil Ground Circuit terminal B and B+. ‹› If the test lamp does not illuminate, test the T8 Ignition Coil Ground Circuit for an open/high resistance. 10. Exchange the affected T8 Ignition Coil assembly with a known good assembly. Note: An open/high resistance on the low reference circuit to the ignition control module may cause a misfire. 11. Start and idle the engine. Observe the misfire counters on the scan tool. ‹› If the misfire or crank/no start is resolved, replace the T8 Ignition Coil/module assembly. ‹› If the misfire does not transfer with the suspect T8 Ignition Coil, measure the resistance of the ignition control circuit. The ignition control circuit should measure less than 5 ohm. If the circuit tests normal, replace the K20 Engine Control Module. Component Testing Static Test * Use the spark plug inspection procedure to verify the integrity of the spark plugs. Replace the spark plug if necessary. Note: An erratic or weak spark is considered a no spark condition. * Use the EL 26792 - HEI spark tester to verify the output of the T8 Ignition Coil. If no spark is detected across the gap of the spark plug tester, replace the T8 Ignition Coil assembly. Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Ignition Coil Replacement (See: Service and Repair) * Spark Plug Replacement (See: Spark Plug/Service and Repair) * Control Module References (See: Testing and Inspection/Programming and Relearning)for replacement, setup, and programming Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Page 3300 Ignition Coil: Service and Repair Ignition Coil Replacement Special Tools EN-6009 - Remover and Installer Ignition Module For equivalent regional tools, refer to Special Tools (See: Computers and Control Systems/Tools and Equipment). Removal Procedure 1. Remove engine sight shield. 2. Disconnect ignition coil wiring harness plug (2) from ignition coil (1). 3. Remove the 2 ignition coil bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Page 3301 4. Install EN-6009 - remover/installer (1) to ignition coil (2). 5. Remove the ignition coil. Installation Procedure 1. Install the ignition coil. 2. Remove EN-6009 - remover (1) from ignition coil (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Page 3302 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 2 ignition coil bolts (1) and tighten to 8 Nm (71 lb in). 4. Connect ignition coil wiring harness plug (2) to ignition coil (1). 5. Install engine sight shield. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations Ignition Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 3306 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 3307 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 3308 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 3309 Ignition Relay: Testing and Inspection Ignition Relay Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description The powertrain relay, is controlled by the engine control module (ECM) depending upon input from the ignition switch. Battery positive voltage is supplied to the relay coil and switch. When the ignition switch is turned to the ON position, the ECM will provide ground on the control circuit of the relay using a low side driver. This will allow voltage through the relay switch contacts to the components. The ECM monitors the voltage level on the control circuit of the relay. Diagnostic Aids The relay electrical contacts may be pitted or sticking. Replace the powertrain relay , if gently tapping or wiggling the powertrain relay causes a change in the relays operation. Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) DTC Type Reference Powertrain Diagnostic Trouble Code (DTC) Type Definitions (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Powertrain Diagnostic Trouble Code (DTC) Type Definitions) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Special Tools EL 43244 - Relay Puller Pliers For equivalent regional tools, refer to Special Tools (See: Computers and Control Systems/Tools and Equipment). Circuit/System Verification Warning An electric fan under the hood can start up even when the engine is not running and can injure you. Keep hands, clothing and tools away from any underhood electric fan. 1. Cycle the ignition from OFF to ON. You should hear and feel an audible click from the KR75 Powertrain Relay. Repeat as necessary in order to verify KR75 Powertrain Relay operation. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 3310 2. Operate the vehicle within the Conditions for running the DTC to verify the DTC does not reset. You may also operate the vehicle within the conditions that you observed from the freeze frame/failure records data. Circuit/System Testing 1. Ignition OFF, disconnect the KR75 Powertrain Relay. 2. Ignition ON, verify a test lamp illuminates between the KR75 Powertrain Relay coil ignition voltage circuit terminal 85 and ground. ‹› If the test lamp does not illuminate, repair the KR75 Powertrain Relay coil ignition voltage circuit for a short to ground or an open/high resistance. Replace the fuse if necessary. 3. Ignition OFF, connect a test lamp between the KR75 Powertrain Relay coil control circuit terminal 86 and the KR75 Powertrain Relay coil ignition voltage circuit terminal 85. ‹› If the test lamp is always ON, test the KR75 Powertrain Relay control circuit for a short to ground. If the circuit tests normal, replace the K20 Engine Control Module. 4. Ignition ON. The test lamp should turn ON. ‹› If the test lamp is always OFF, test the KR75 Powertrain Relay ECM control circuit for a short to voltage or an open/high resistance. If circuit tests normal, replace the K20 Engine Control Module. Note: The ignition voltage circuit is between the KR75 Powertrain Relay and the ECM. The ignition voltage is a feedback circuit. 5. Install a 20 A fused jumper wire between the KR75 Powertrain Relay switch B+ circuit terminal 30 and the KR75 Powertrain Relay switch ignition voltage circuit terminal 87. 6. Attempt to start the engine. The engine should start. ‹› If the engine does not start, test the ignition voltage circuit between the KR75 Powertrain Relay and the K20 Engine Control Module for a short to ground or for an open/high resistance. If the circuit tests normal, replace the K20 Engine Control Module. 7. If all circuits test normal, test or replace the KR75 Powertrain Relay. Component Testing Relay Test 1. Ignition OFF, remove the KR75 Powertrain Relay from the electrical center with the EL 43244 Relay Puller Pliers. 2. Test for 70-110 ohm between terminals 85 and 86. ‹› If not within the specified range, replace the KR75 Powertrain Relay. 3. Test for infinite resistance between the following terminals: * 30 and 86 * 30 and 87 * 30 and 85 * 85 and 87 ‹› If not the specified value, replace the KR75 Powertrain Relay. 4. Install a 20 A fused jumper wire between KR75 Powertrain Relay terminal 85 and 12 V. Install a jumper wire between KR75 Powertrain Relay terminal 86 and ground. Test for less than 2 ohm between terminals 30 and 87. ‹› If greater than the specified range, replace the KR75 Powertrain Relay. Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) * Control Module References (See: Testing and Inspection/Programming and Relearning)for ECM replacement, setup, and programming Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views Knock Sensor: Locations Disassembled Views Disassembled Views Engine Block Assembly - 1.4L LDD 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Engine Block 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views > Page 3315 16 - Oil Pan Bolt 17 - Oil Pan Drain Plug Seal Ring 18 - Oil Pan Drain Plug 19 - Crankshaft Position Sensor Bolt 20 - Crankshaft Position Sensor 21 - Crankshaft Position Sensor Seal Ring 22 Crankshaft Bearing Cap Tie Plate Bolt (M8) 23 - Crankshaft Position Sensor Reluctor Ring 24 Flywheel Bolt 25 - Engine Flywheel 26 - Crankshaft Rear Oil Seal 27 - Crankshaft Position Sensor Reluctor Ring Bolt 28 - Connecting Rod Bearing Cap Bolt 29 - Connecting Rod Bearing Cap 30 Lower Connecting Rod Bearing 31 - Upper Connecting Rod Bearing 32 - Connecting Rod 33 Piston Pin 34 - Piston 35 - Piston Oil Ring (With oil Ring Spacer) 36 - Lower Compression Ring 37 - Upper Compression Ring Engine Block Assembly - 1.4L LUH and LUJ Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views > Page 3316 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Cylinder Head 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Baffle 16 - Oil Pan Baffle Bolt 17 - Oil Pan 18 - Oil Pan Bolt 19 - Oil Pan Drain Plug 20 - Crankshaft Position Sensor Bolt 21 - Crankshaft Position Sensor 22 - Crankshaft Position Sensor Seal Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views > Page 3317 23 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 24 - Piston Oil Nozzle 25 - Crankshaft Position Sensor Reluctor Ring 26 - Crankshaft Position Sensor Reluctor Ring Bolt 27 - Crankshaft Rear Oil Seal 28 - Engine Flywheel (Two-Mass) 29 - Engine Flywheel Bolt 30 - Connecting Rod Bearing Cap Bolt 31 - Connecting Rod Bearing Cap 32 - Lower Connecting Rod Bearing 33 - Upper Connecting Rod Bearing 34 - Connecting Rod 35 - Piston Pin 36 - Piston Pin Retainer 37 - Piston Pin Retainer 38 - Piston 39 - Piston Oil Ring (With Oil Ring Spacer) 40 - Lower Compression Ring 41 - Upper Compression Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views > Page 3318 Knock Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Left Rear (LUJ) 1 - B111 Turbocharger Boost Pressure Sensor 2 - T8 Ignition Coil 3 - B68 Knock Sensor (KS) 4 Q38 Throttle Body 5 - B34 Engine Coolant Temperature Sensor Lower Rear of the Engine Components 1 of 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views > Page 3319 1 - B68 Knock Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3320 Knock Sensor: Description and Operation Knock Sensor System Description Circuit/System Description The knock sensor system enables the engine control module (ECM) to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The ECM uses the knock sensor system to test for abnormal engine noise that may indicate detonation, also known as spark knock. Sensor Description This knock sensor system uses one or two flat response dual-wire sensors. The sensor uses piezo-electric crystal technology that produces an alternating current (AC) voltage signal of varying amplitude and frequency based on the engine vibration or noise level. The amplitude and frequency are dependant upon the level of knock that the knock sensor detects. The ECM receives the knock sensor signal through 2 isolated signal circuits. If the ECM has determined that knock is present, it will retard the ignition timing to attempt to reduce the knock. The ECM is capable of controlling spark retard on an individual cylinder basis. The ECM will always try to work back to a zero compensation level, or no spark retard. knock sensor diagnostics are calibrated to detect faults with the knock sensor circuitry inside the ECM, the knock sensor wiring, or the knock sensor voltage output. Some diagnostics are also calibrated to detect constant noise from an outside influence such as a loose/damaged component or excessive mechanical engine noise. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3321 Knock Sensor: Service and Repair Knock Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations Ignition Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 3326 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 3327 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 3328 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 3329 Ignition Relay: Testing and Inspection Ignition Relay Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description The powertrain relay, is controlled by the engine control module (ECM) depending upon input from the ignition switch. Battery positive voltage is supplied to the relay coil and switch. When the ignition switch is turned to the ON position, the ECM will provide ground on the control circuit of the relay using a low side driver. This will allow voltage through the relay switch contacts to the components. The ECM monitors the voltage level on the control circuit of the relay. Diagnostic Aids The relay electrical contacts may be pitted or sticking. Replace the powertrain relay , if gently tapping or wiggling the powertrain relay causes a change in the relays operation. Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) DTC Type Reference Powertrain Diagnostic Trouble Code (DTC) Type Definitions (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Powertrain Diagnostic Trouble Code (DTC) Type Definitions) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Special Tools EL 43244 - Relay Puller Pliers For equivalent regional tools, refer to Special Tools (See: Computers and Control Systems/Tools and Equipment). Circuit/System Verification Warning An electric fan under the hood can start up even when the engine is not running and can injure you. Keep hands, clothing and tools away from any underhood electric fan. 1. Cycle the ignition from OFF to ON. You should hear and feel an audible click from the KR75 Powertrain Relay. Repeat as necessary in order to verify KR75 Powertrain Relay operation. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 3330 2. Operate the vehicle within the Conditions for running the DTC to verify the DTC does not reset. You may also operate the vehicle within the conditions that you observed from the freeze frame/failure records data. Circuit/System Testing 1. Ignition OFF, disconnect the KR75 Powertrain Relay. 2. Ignition ON, verify a test lamp illuminates between the KR75 Powertrain Relay coil ignition voltage circuit terminal 85 and ground. ‹› If the test lamp does not illuminate, repair the KR75 Powertrain Relay coil ignition voltage circuit for a short to ground or an open/high resistance. Replace the fuse if necessary. 3. Ignition OFF, connect a test lamp between the KR75 Powertrain Relay coil control circuit terminal 86 and the KR75 Powertrain Relay coil ignition voltage circuit terminal 85. ‹› If the test lamp is always ON, test the KR75 Powertrain Relay control circuit for a short to ground. If the circuit tests normal, replace the K20 Engine Control Module. 4. Ignition ON. The test lamp should turn ON. ‹› If the test lamp is always OFF, test the KR75 Powertrain Relay ECM control circuit for a short to voltage or an open/high resistance. If circuit tests normal, replace the K20 Engine Control Module. Note: The ignition voltage circuit is between the KR75 Powertrain Relay and the ECM. The ignition voltage is a feedback circuit. 5. Install a 20 A fused jumper wire between the KR75 Powertrain Relay switch B+ circuit terminal 30 and the KR75 Powertrain Relay switch ignition voltage circuit terminal 87. 6. Attempt to start the engine. The engine should start. ‹› If the engine does not start, test the ignition voltage circuit between the KR75 Powertrain Relay and the K20 Engine Control Module for a short to ground or for an open/high resistance. If the circuit tests normal, replace the K20 Engine Control Module. 7. If all circuits test normal, test or replace the KR75 Powertrain Relay. Component Testing Relay Test 1. Ignition OFF, remove the KR75 Powertrain Relay from the electrical center with the EL 43244 Relay Puller Pliers. 2. Test for 70-110 ohm between terminals 85 and 86. ‹› If not within the specified range, replace the KR75 Powertrain Relay. 3. Test for infinite resistance between the following terminals: * 30 and 86 * 30 and 87 * 30 and 85 * 85 and 87 ‹› If not the specified value, replace the KR75 Powertrain Relay. 4. Install a 20 A fused jumper wire between KR75 Powertrain Relay terminal 85 and 12 V. Install a jumper wire between KR75 Powertrain Relay terminal 86 and ground. Test for less than 2 ohm between terminals 30 and 87. ‹› If greater than the specified range, replace the KR75 Powertrain Relay. Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) * Control Module References (See: Testing and Inspection/Programming and Relearning)for ECM replacement, setup, and programming Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle Camshaft Position Sensor: Customer Interest Engine - Lack of Power with Multiple DTCs or Rattle TECHNICAL Bulletin No.: 10-06-04-016 Date: December 20, 2010 Subject: Engine Lack of Power with DTCs P0011, P0014, P000A, P000B, P0012, P0015 or Engine Rattle Noise (Remove Oil Filters from Intake and Exhaust Camshaft Position Actuator Solenoid Valves) Models: 2008-2011 Chevrolet Aveo 2011 Chevrolet Cruze (US and Canada) 2009-2011 Chevrolet Cruze (Export Only) 2008-2009 Pontiac G3, Wave 2008-2009 Saturn Astra Condition Some customers may comment on lack of power with the following DTCs or an engine rattle noise from the sprockets. Cruze GEN3 1.6/1.8D - P0011: Intake Camshaft Position (CMP) System Performance - P0014: Exhaust Camshaft Position (CMP) System Performance - P000A: Intake Camshaft Position System Slow Response - P000B: Exhaust Camshaft Position System Slow Response Aveo GEN3 1.4D - P0012: Intake Camshaft Position (CMP) System Performance Bank 1-Retarded - P0015: Exhaust Camshaft Position (CMP) System Performance Bank 1-Retarded Aveo/G3/Wave Gen3 1.6D - P0011: Intake Camshaft Position (CMP) System Performance Bank 1 - P0014: Exhaust Camshaft Position (CMP) System Performance Bank 1 Correction Remove four oil filters from the intake and exhaust camshaft position actuator solenoid valves. 1. Open the hood. 2. Disconnect the negative battery cable. 3. Disconnect the camshaft position actuator solenoid valve connectors. 4. Remove the power steering line bracket bolt and reposition the bracket (for 1.6/1.8L only). 5. Disconnect PCV pipe and reposition (for 1.6/1.8L only). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 3340 6. Remove the camshaft position actuator solenoid valve bolts. 7. Remove the camshaft position actuator solenoid valves and seals. 8. Check whether the filter is broken or not (1). 9. Remove the four filters (intake and exhaust). 1. Broken Filter: Remove filter with a blunt tool. 2. Unbroken Filter 1. Locate the filter hinge between the holes. 2. Cut the filter hinge slightly. Caution Do not scratch the valve surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 3341 3. Remove the filter with a blunt tool. 10. Install the camshaft position actuator solenoid valves and seals. Coat the seal with clean engine oil prior to installation. 11. Install the camshaft position actuator solenoid valve bolts. Tighten Tighten the bolts to 6 Nm (53 lb in). 12. Connect the camshaft position actuator solenoid valve connectors. 13. Reposition and install the PCV pipe (for 1.6/1.8 only). 14. Reposition the power steering bracket and install the power steering line bracket bolt (for 1.6/1.8 only). 15. Connect the negative battery cable. Note If an engine rattle noise is heard after removing the filters, refer to SI for further diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle Camshaft Position Sensor: All Technical Service Bulletins Engine - Lack of Power with Multiple DTCs or Rattle TECHNICAL Bulletin No.: 10-06-04-016 Date: December 20, 2010 Subject: Engine Lack of Power with DTCs P0011, P0014, P000A, P000B, P0012, P0015 or Engine Rattle Noise (Remove Oil Filters from Intake and Exhaust Camshaft Position Actuator Solenoid Valves) Models: 2008-2011 Chevrolet Aveo 2011 Chevrolet Cruze (US and Canada) 2009-2011 Chevrolet Cruze (Export Only) 2008-2009 Pontiac G3, Wave 2008-2009 Saturn Astra Condition Some customers may comment on lack of power with the following DTCs or an engine rattle noise from the sprockets. Cruze GEN3 1.6/1.8D - P0011: Intake Camshaft Position (CMP) System Performance - P0014: Exhaust Camshaft Position (CMP) System Performance - P000A: Intake Camshaft Position System Slow Response - P000B: Exhaust Camshaft Position System Slow Response Aveo GEN3 1.4D - P0012: Intake Camshaft Position (CMP) System Performance Bank 1-Retarded - P0015: Exhaust Camshaft Position (CMP) System Performance Bank 1-Retarded Aveo/G3/Wave Gen3 1.6D - P0011: Intake Camshaft Position (CMP) System Performance Bank 1 - P0014: Exhaust Camshaft Position (CMP) System Performance Bank 1 Correction Remove four oil filters from the intake and exhaust camshaft position actuator solenoid valves. 1. Open the hood. 2. Disconnect the negative battery cable. 3. Disconnect the camshaft position actuator solenoid valve connectors. 4. Remove the power steering line bracket bolt and reposition the bracket (for 1.6/1.8L only). 5. Disconnect PCV pipe and reposition (for 1.6/1.8L only). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 3347 6. Remove the camshaft position actuator solenoid valve bolts. 7. Remove the camshaft position actuator solenoid valves and seals. 8. Check whether the filter is broken or not (1). 9. Remove the four filters (intake and exhaust). 1. Broken Filter: Remove filter with a blunt tool. 2. Unbroken Filter 1. Locate the filter hinge between the holes. 2. Cut the filter hinge slightly. Caution Do not scratch the valve surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 10-06-04-016 > Dec > 10 > Engine - Lack of Power with Multiple DTCs or Rattle > Page 3348 3. Remove the filter with a blunt tool. 10. Install the camshaft position actuator solenoid valves and seals. Coat the seal with clean engine oil prior to installation. 11. Install the camshaft position actuator solenoid valve bolts. Tighten Tighten the bolts to 6 Nm (53 lb in). 12. Connect the camshaft position actuator solenoid valve connectors. 13. Reposition and install the PCV pipe (for 1.6/1.8 only). 14. Reposition the power steering bracket and install the power steering line bracket bolt (for 1.6/1.8 only). 15. Connect the negative battery cable. Note If an engine rattle noise is heard after removing the filters, refer to SI for further diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Disassembled Views Camshaft Position Sensor: Locations Disassembled Views Disassembled Views Engine Front Cover And Oil Pump Assembly (1 of 2) 1 - Camshaft Position Actuator Solenoid Valve Bolt 2 - Intake Camshaft Position Actuator Solenoid Valve 3 - Exhaust Camshaft Position Actuator Solenoid Valve 4 - Intake Camshaft Position Sensor Bolt 5 - Intake Camshaft Position Sensor 6 - Intake Camshaft Position Sensor Seal Ring 7 - Engine Front Cover 8 - Engine Front Cover Gasket 9 - Exhaust Camshaft Position Sensor Seal Ring 10 Exhaust Camshaft Position Sensor 11 - Exhaust Camshaft Position Sensor Bolt 12 - Engine Front Cover Oil Gallery Plug 13 - Engine Front Cover Oil Gallery Plug Seal Ring 14 - Oil Pressure Relief Valve Piston 15 - Oil Pressure Relief Valve Spring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 3351 16 - Oil Pressure Relief Valve Plug 17 - Engine Front Cover Bolt (M10) 18 - Crankshaft Front Oil Seal 19 - Engine Front Cover Bolt (M6) 20 - Water Drain Plug Seal Ring 21 - Water Drain Plug 22 Exhaust Camshaft Position Actuator Solenoid Valve Bolt Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 3352 Camshaft Position Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Front (LUJ) 1 - Q6E Camshaft Position Actuator Solenoid Valve - Exhaust 2 - B23E Camshaft Position Sensor Exhaust 3 - B37 Engine Oil Pressure Switch 4 - B52A Heated Oxygen Sensor 1 5 - Q42 Turbocharger Wastegate Solenoid Valve 6 - Q2 A/C Compressor Clutch Engine Components - Right Rear (LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 3353 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3354 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Open hood. Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 2. Disconnect the camshaft position sensor wiring harness plug (1). Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 3. Remove the camshaft position sensor bolt (3). 4. Remove the camshaft position sensor (2) and the seal ring (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3355 Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 1. Install the camshaft position sensor (2) and the seal ring (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 2. Install the camshaft position sensor bolt (3) and tighten to 8 Nm (71 lb in). Note: Graphic shows exhaust camshaft position sensor. Use same procedure for Intake camshaft position sensor. 3. Connect the camshaft position sensor wiring harness plug (1). 4. After replacement of an camshaft position sensor, use a scan tool to speed up learn function. Refer to Engine Control Module Programming and Setup (LUW, LUJ) (See: Testing and Inspection/Programming and Relearning/Engine Control Module Programming and Setup) 5. Close hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views Crankshaft Position Sensor: Locations Disassembled Views Disassembled Views Engine Block Assembly - 1.4L LDD 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Engine Block 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 3360 16 - Oil Pan Bolt 17 - Oil Pan Drain Plug Seal Ring 18 - Oil Pan Drain Plug 19 - Crankshaft Position Sensor Bolt 20 - Crankshaft Position Sensor 21 - Crankshaft Position Sensor Seal Ring 22 Crankshaft Bearing Cap Tie Plate Bolt (M8) 23 - Crankshaft Position Sensor Reluctor Ring 24 Flywheel Bolt 25 - Engine Flywheel 26 - Crankshaft Rear Oil Seal 27 - Crankshaft Position Sensor Reluctor Ring Bolt 28 - Connecting Rod Bearing Cap Bolt 29 - Connecting Rod Bearing Cap 30 Lower Connecting Rod Bearing 31 - Upper Connecting Rod Bearing 32 - Connecting Rod 33 Piston Pin 34 - Piston 35 - Piston Oil Ring (With oil Ring Spacer) 36 - Lower Compression Ring 37 - Upper Compression Ring Engine Block Assembly - 1.4L LUH and LUJ Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 3361 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Cylinder Head 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Baffle 16 - Oil Pan Baffle Bolt 17 - Oil Pan 18 - Oil Pan Bolt 19 - Oil Pan Drain Plug 20 - Crankshaft Position Sensor Bolt 21 - Crankshaft Position Sensor 22 - Crankshaft Position Sensor Seal Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 3362 23 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 24 - Piston Oil Nozzle 25 - Crankshaft Position Sensor Reluctor Ring 26 - Crankshaft Position Sensor Reluctor Ring Bolt 27 - Crankshaft Rear Oil Seal 28 - Engine Flywheel (Two-Mass) 29 - Engine Flywheel Bolt 30 - Connecting Rod Bearing Cap Bolt 31 - Connecting Rod Bearing Cap 32 - Lower Connecting Rod Bearing 33 - Upper Connecting Rod Bearing 34 - Connecting Rod 35 - Piston Pin 36 - Piston Pin Retainer 37 - Piston Pin Retainer 38 - Piston 39 - Piston Oil Ring (With Oil Ring Spacer) 40 - Lower Compression Ring 41 - Upper Compression Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Disassembled Views > Page 3363 Crankshaft Position Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Right Rear (LUJ) 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3364 Crankshaft Position Sensor: Diagrams Component Connector End Views B26 Crankshaft Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3365 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The crankshaft position sensor system variation learn procedure is required when the following service procedures have been performed, regardless of whether DTC P0315 00 is set: * Engine replacement * Engine control module (ECM) replacement * Crankshaft damper replacement * Crankshaft replacement * Crankshaft Position Sensor Replacement * Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Note: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the crankshaft position sensor system variation learn procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * Crankshaft Position Sensor activity - If there is a crankshaft position sensor condition, refer to the applicable DTC that set. * Camshaft position signal activity - If there is a camshaft position sensor signal condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT) - If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P0315 00, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select the Crankshaft Position System Variation Learn procedure and perform the following: 1. Observe the fuel cut-off for the applicable engine. 2. Block the drive wheels. 3. Set the parking brake. 4. Place the vehicles transmission in Park or Neutral. 5. Turn the air conditioning (A/C) OFF. 6. Cycle the ignition from OFF to ON. 7. Apply and hold the brake pedal for the duration of the procedure. 8. Start and idle the engine. 9. Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 10. Release the throttle when fuel cut-off occurs. ‹› Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC P0315 00 ran and passed, the crankshaft position sensor variation learn procedure is complete. If the scan tool indicates DTC P0315 00 failed or did not run, refer to DTC P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 5. Turn OFF the ignition for 30 s after the learn procedure is completed successfully. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3366 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair Key and Lock Cylinder Coding Ignition Lock Cylinder The ignition lock cylinder uses 8 key cut positions, 1-8. The tumbler positions are staggered from side to side, four on one side and four on the other. Note: The tumblers (5) are not self-retaining and must be held in place if the key is not fully inserted into the lock cylinder or until the cylinder (2) is assembled into the case assembly (8). 1. Hold the cylinder assembly (2) so that the retainer pin pocket is facing upward. 2. Insert one tumbler spring (4) into each of the 4 spring wells. 3. The first tumbler (5) to be loaded will be the first key cut position, the first number in the key code. Install the first tumbler in the slot nearest the head of the lock cylinder. Install the remaining tumblers following the key code into the slots at the key cut positions 3, 5 and 7. It may be necessary to move the sidebar (already pre-assembled into the cylinder assembly) out slightly to fully install the tumbler into the correct slot. 4. Check the correct loading by holding the tumblers (5) in position and fully inserting the key into the cylinder assembly (2). All tumblers and the sidebar should be flushed with the outside diameter of the cylinder assembly body. 5. Rotate the cylinder assembly (2) so that the retention lug is facing upward and then remove the key, always holding all tumblers so they do not fall out. 6. Insert one tumbler spring (4) into each of the 4 spring wells. 7. The first tumbler (5) to be loaded will be the second key cut position, the second number in the key code. Install the tumbler in the slot nearest the head of the lock cylinder. Install the remaining tumblers following the key code into the slots at the key cut positions 4, 6 and 8. 8. Check for the correct loading by holding the tumblers (5) in position and fully inserting the key into the cylinder assembly (2). 9. Lightly lubricate the tumbler (5) surfaces and the small detent recess on the side of the cylinder assembly (2) using the lubrication provided. 10. With the key fully inserted, rotate the cylinder assembly so that the side with the retaining pin (7) pocket is facing upward. 11. Insert the retaining pin spring (6) and then retaining pin (7) into the pocket located behind the 4 tumblers. The retaining pin spring and retaining pin are not self-retaining and must be held in place until the cylinder is installed into the case assembly (8). 12. With the key fully inserted into the cylinder assembly and the retaining pin (7) fully depressed into the cylinder, align the retainer lug on the cylinder with the groove on the inside diameter of the case assembly (8). This groove extends the full length of the case assembly. 13. Install the cylinder assembly into the case assembly (8) being very careful to hold the retainer pin spring (6) and retainer pin (7) in the cylinder until they enter into the case assembly. With the cylinder fully inserted into the case assembly, rotate the cylinder counterclockwise until the retainer pin (7) snaps into place limiting the rotation of the cylinder assembly. 14. With the cylinder assembly in the Off-Lock position, insert the detent rod (1) into the hole in the side of the case assembly (8). Install the anti-rattle spring (3) into the case assembly over the detent spring. The anti-rattle spring should capture the detent ball and spring in the case assembly. Make sure both ends of the anti-rattle spring (3) are fully seated, pressed into, the case assembly. 15. With the cylinder assembly in the Off-Lock position, insert the detent rod (1) into the hole in the side of the case assembly (8). Install the anti-rattle spring (3) into the case assembly over the detent spring. The anti-rattle spring should capture the detent ball and spring in the case assembly. Make sure both ends of the anti-rattle spring (3) are fully seated, pressed into, the case assembly. Front Side Door Lock Cylinder Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Page 3371 1. Rotate the cylinder (8) so that the side with the tumbler spring wells faces up. 2. Insert the tumbler springs (4) into the 4 spring wells. 3. Install the tumbler (10) for key cut position 3 in the slot closest to the cylinder head. Install the remaining tumblers, key cut positions 5, 7 and 9, following the key code and same process. Press the tumblers in place until they are secure. 4. Check the correct loading of the tumblers by inserting the key into the cylinder. All tumblers should be flushed with the lock cylinder body. 5. Turn the cylinder so the side with the other tumbler spring wells faces up. 6. Insert the tumbler springs (4) into the 4 spring wells. 7. The first tumbler closest to the head of the lock cylinder to be loaded will be the fourth key cut position. Install the remaining tumblers for key cut positions 6, 8 and 10. Press the tumblers in place until they are secure. 8. Check the correct loading of the tumblers by inserting the key into the cylinder. All of the tumblers should be flushed with the lock cylinder body. 9. Apply lubricant to the cylinder body and tumbler surfaces along with a small amount in the head of the cylinder using the supplied lubricant. 10. Install the retainer (5) into the spring wells in the head of the lock cylinder. 11. Snap the shutter (7) into the cylinder. 12. Assemble the cylinder into the case (3). 13. Align dimples of the cylinder cap (6) with the 4 recesses in the cap. Secure by pressing the cap into place with light hand pressure. 14. Assemble the rod clip (2) to the lever (1). 15. Assemble the lever (1) to the lock. Use driver unit (11) to retain the lever assembly. 16. Assemble the gasket to the lock. 17. Insert the key into the lock and function the lock to check for proper assembly and smooth operation. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views Knock Sensor: Locations Disassembled Views Disassembled Views Engine Block Assembly - 1.4L LDD 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Engine Block 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views > Page 3376 16 - Oil Pan Bolt 17 - Oil Pan Drain Plug Seal Ring 18 - Oil Pan Drain Plug 19 - Crankshaft Position Sensor Bolt 20 - Crankshaft Position Sensor 21 - Crankshaft Position Sensor Seal Ring 22 Crankshaft Bearing Cap Tie Plate Bolt (M8) 23 - Crankshaft Position Sensor Reluctor Ring 24 Flywheel Bolt 25 - Engine Flywheel 26 - Crankshaft Rear Oil Seal 27 - Crankshaft Position Sensor Reluctor Ring Bolt 28 - Connecting Rod Bearing Cap Bolt 29 - Connecting Rod Bearing Cap 30 Lower Connecting Rod Bearing 31 - Upper Connecting Rod Bearing 32 - Connecting Rod 33 Piston Pin 34 - Piston 35 - Piston Oil Ring (With oil Ring Spacer) 36 - Lower Compression Ring 37 - Upper Compression Ring Engine Block Assembly - 1.4L LUH and LUJ Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views > Page 3377 1 - Transmission Guide Sleeve 2 - Transmission Guide Sleeve 3 - Cylinder Head Guide Sleeve 4 Cylinder Head 5 - Cylinder Head Guide Sleeve 6 - Knock Sensor 7 - Knock Sensor Bolt 8 - Upper Crankshaft Thrust Bearing 9 - Upper Crankshaft Bearing 10 - Crankshaft 11 - Lower Crankshaft Bearing 12 - Lower Crankshaft Thrust Bearing 13 - Crankshaft Bearing Cap Tie Plate 14 Crankshaft Bearing Cap Tie Plate Bolt (M10) 15 - Oil Pan Baffle 16 - Oil Pan Baffle Bolt 17 - Oil Pan 18 - Oil Pan Bolt 19 - Oil Pan Drain Plug 20 - Crankshaft Position Sensor Bolt 21 - Crankshaft Position Sensor 22 - Crankshaft Position Sensor Seal Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views > Page 3378 23 - Crankshaft Bearing Cap Tie Plate Bolt (M8) 24 - Piston Oil Nozzle 25 - Crankshaft Position Sensor Reluctor Ring 26 - Crankshaft Position Sensor Reluctor Ring Bolt 27 - Crankshaft Rear Oil Seal 28 - Engine Flywheel (Two-Mass) 29 - Engine Flywheel Bolt 30 - Connecting Rod Bearing Cap Bolt 31 - Connecting Rod Bearing Cap 32 - Lower Connecting Rod Bearing 33 - Upper Connecting Rod Bearing 34 - Connecting Rod 35 - Piston Pin 36 - Piston Pin Retainer 37 - Piston Pin Retainer 38 - Piston 39 - Piston Oil Ring (With Oil Ring Spacer) 40 - Lower Compression Ring 41 - Upper Compression Ring Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views > Page 3379 Knock Sensor: Locations Powertrain Component Views Powertrain Component Views Engine Components - Left Rear (LUJ) 1 - B111 Turbocharger Boost Pressure Sensor 2 - T8 Ignition Coil 3 - B68 Knock Sensor (KS) 4 Q38 Throttle Body 5 - B34 Engine Coolant Temperature Sensor Lower Rear of the Engine Components 1 of 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Disassembled Views > Page 3380 1 - B68 Knock Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3381 Knock Sensor: Description and Operation Knock Sensor System Description Circuit/System Description The knock sensor system enables the engine control module (ECM) to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The ECM uses the knock sensor system to test for abnormal engine noise that may indicate detonation, also known as spark knock. Sensor Description This knock sensor system uses one or two flat response dual-wire sensors. The sensor uses piezo-electric crystal technology that produces an alternating current (AC) voltage signal of varying amplitude and frequency based on the engine vibration or noise level. The amplitude and frequency are dependant upon the level of knock that the knock sensor detects. The ECM receives the knock sensor signal through 2 isolated signal circuits. If the ECM has determined that knock is present, it will retard the ignition timing to attempt to reduce the knock. The ECM is capable of controlling spark retard on an individual cylinder basis. The ECM will always try to work back to a zero compensation level, or no spark retard. knock sensor diagnostics are calibrated to detect faults with the knock sensor circuitry inside the ECM, the knock sensor wiring, or the knock sensor voltage output. Some diagnostics are also calibrated to detect constant noise from an outside influence such as a loose/damaged component or excessive mechanical engine noise. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3382 Knock Sensor: Service and Repair Knock Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications Ignition System Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3386 Spark Plug: Application and ID Ignition System Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3387 Spark Plug: Testing and Inspection Spark Plug Inspection Spark Plug Usage 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications ( See: Application and ID) for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: * Spark plug fouling-Colder plug * Pre-ignition causing spark plug and/or engine damage-Hotter plug Spark Plug Inspection 1. Inspect the terminal post (1) for damage. * Inspect for a bent or broken terminal post (1). * Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: * Inspect the spark plug boot for damage. * Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3388 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. * Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications (See: Application and ID). An excessively wide electrode gap can prevent correct spark plug operation. * Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Application and ID). Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. * Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). * Inspect for a broken or worn side electrode (3). * Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. 5. A rattling sound indicates internal damage. 6. A loose center electrode (4) reduces the spark intensity. * Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. * Inspect for worn or missing platinum pads on the electrodes (3, 4) If equipped. * Inspect for excessive fouling. * Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Spark Plug Visual Inspection 1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: * Rich fuel mixtures * Leaking fuel injectors * Excessive fuel pressure * Restricted air filter element * Incorrect combustion * Reduced ignition system voltage output * Weak coils * Worn ignition wires * Incorrect spark plug gap * Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. * Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3389 Spark Plug: Service and Repair Spark Plug Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Shift Interlock Solenoid: Diagrams Component Connector End Views S3 Automatic Transmission Shift Lever (MH8) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 3396 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure Note: The automatic transmission shift lock control actuator is part of the automatic transmission control and cannot be removed separately. Remove the shift lock control actuator. Refer to Transmission Control Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Shifter A/T/Service and Repair/Transmission Control Replacement). Installation Procedure Install the shift lock control actuator. Refer to Transmission Control Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Shifter A/T/Service and Repair/Transmission Control Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Shift Solenoid Valve State and Gear Ratio Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 3400 Shift Solenoid: Service and Repair Control Solenoid Valve and Transmission Control Module Assembly Replacement Removal Procedure 1. Remove the transmission control valve body cover. Refer to Control Valve Body Cover Replacement (LDE, LUW) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement)Control Valve Body Cover Replacement (LLU, LUJ) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement). 2. Disconnect the output speed sensor electrical connector (2). 3. Disconnect the shift position switch electrical connector (3). 4. Disconnect the input speed sensor electrical connector (1). 5. Remove the 3 control valve body bolts (1) M5 x 40.5. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 3401 6. Remove the 12 control valve body bolts (2) M6 x 97. 7. Remove the control solenoid valve assembly (3) with transmission control module. Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 8. Remove the control solenoid valve assembly filter plate (4). Discard the filter plate. It is not reusable. 9. Inspect the pressure switch seals for damage or contamination. Replace the control solenoid valve assembly as necessary. 10. Inspect the channel plate bolt pass through holes for damage or burnelling. Any damage could cause leaking. Replace as necessary. Installation Procedure Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 1. Install a NEW control solenoid valve assembly filter plate (4) to prevent fluid leaks past the fluid seals. 2. Install the control solenoid valve assembly (3) with transmission control module. 3. Hand start the control valve body bolts (1, 2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 3402 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Secure the 12 control valve body bolts (2) M6 x 97 and tighten in sequence to 12 Nm(106 lb in). 5. Secure the 3 control valve body bolts (1) M5 x 40.5 and tighten in sequence to 8 Nm(71 lb in). 6. Connect the input speed sensor electrical connector (1). 7. Connect the output speed sensor electrical connector (2). 8. Install the transmission control valve body cover. Refer to Control Valve Body Cover Replacement (LDE, LUW) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement)Control Valve Body Cover Replacement (LLU, LUJ) (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement). 9. After repairs, refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for programming and set up procedures. 10. Perform the transmission adaptive values learn. Refer to Transmission Adaptive Values Learn (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair Automatic or Manual Transmission Control Lever Trim Cover Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Recalls for Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues Control Module: Recalls Campaign - Thermostat Sticks Open Causes Shift Issues SERVICE UPDATE Bulletin No.: 10399A Date: December 02, 2010 Subject: 10399A - Service Update for Inventory and Customer Vehicles - Powertrain Improvements - Thermostat Sticks in Open Position and Shift Quality - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with a 1.4L Turbo Engine (LUJ) Supercede: The Subject and Purpose in this bulletin are being revised to advise that the new ECM calibration will also address shift quality issues.Please discard all copies of bulletin 10399, issued November 2010. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to reprogram the engine control module (ECM) on certain 2011 model year Chevrolet Cruze vehicles equipped with a 1.4L turbo engine (LUJ). These vehicles may have a condition where the thermostat sticks in the open position. If this occurs, diagnostic codes will be set and the Service Vehicle Soon light/message will illuminate. These vehicles may also have transmission shift quality issues due to calibration values. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. Additionally, a list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should also be checked for vehicle eligibility. Parts Information No parts are required for this update. Service Procedure Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 11/29/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming. 2. Reprogram the engine control module (ECM) and transmission control module (TCM) in sequence. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI or Tech 2(R) to the vehicle. If using MDI, connect to programming terminal with the cable (USB or LAN). 2. Select J-2534 MDI or J-2534 Tech 2(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Recalls for Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues > Page 3418 3. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. 4. Follow the on-screen instructions. 3. Clear all DTCs using the GDS or Tech 2(R). Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues Control Module: All Technical Service Bulletins Campaign - Thermostat Sticks Open Causes Shift Issues SERVICE UPDATE Bulletin No.: 10399A Date: December 02, 2010 Subject: 10399A - Service Update for Inventory and Customer Vehicles - Powertrain Improvements - Thermostat Sticks in Open Position and Shift Quality - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with a 1.4L Turbo Engine (LUJ) Supercede: The Subject and Purpose in this bulletin are being revised to advise that the new ECM calibration will also address shift quality issues.Please discard all copies of bulletin 10399, issued November 2010. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to reprogram the engine control module (ECM) on certain 2011 model year Chevrolet Cruze vehicles equipped with a 1.4L turbo engine (LUJ). These vehicles may have a condition where the thermostat sticks in the open position. If this occurs, diagnostic codes will be set and the Service Vehicle Soon light/message will illuminate. These vehicles may also have transmission shift quality issues due to calibration values. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. Additionally, a list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should also be checked for vehicle eligibility. Parts Information No parts are required for this update. Service Procedure Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 11/29/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming. 2. Reprogram the engine control module (ECM) and transmission control module (TCM) in sequence. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI or Tech 2(R) to the vehicle. If using MDI, connect to programming terminal with the cable (USB or LAN). 2. Select J-2534 MDI or J-2534 Tech 2(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues > Page 3424 3. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. 4. Follow the on-screen instructions. 3. Clear all DTCs using the GDS or Tech 2(R). Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3425 Control Module: Locations Powertrain Component Views Transmission Components (MH8) 1 - T12 Automatic Transmission Assembly 2 - X1 Transmission Control Module X1 3 - T12 Automatic Transmission Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair Transmission Position Switch/Sensor: Service and Repair Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Special Tools DT-41229 - Manual Shaft Pin Installer For equivalent regional tools, refer to Special Tools (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Tools and Equipment). Removal Procedure 1. Remove the control valve body. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 2. Remove the manual shaft detent lever hub pin (1) using a pry bar and pliers. 3. Remove and DISCARD the manual shift shaft pin (5). 4. Remove the manual shaft (2). 5. Disconnect the actuator rod (3) from the detent lever assembly. Do not remove the actuator rod from the transmission case. 6. Remove the manual shaft detent (with shift position switch) lever assembly (4). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Page 3431 1. Connect the actuator rod (3) to the detent lever assembly. 2. Install the manual shaft detent (with shift position switch) lever assembly (4). 3. Install the manual shaft (2). 4. Install the manual shaft detent lever hub pin (1) to height of 7.9 mm (0.38 in) (b). Caution: Use J 41229 to install the manual shaft pin at the correct height in order to properly secure the manual shaft. If you install the pin too deep, the case bore may crack. 5. Install the NEW manual shift shaft pin (5) using DT-41229 - pin installer. Use a NEW pin to ensure proper engagement with the case. 6. Inspect pin installed height is within 7.2-8.2 mm (0.28-0.32 in) (a). 7. Install the control valve body. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 8. Perform the transmission adaptive values learn procedure. Refer to Transmission Adaptive Values Learn (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Transmission Speed Sensor: Locations Component Location 1 - Reaction Carrier Assembly 2 - Control Valve Body Assembly 3 - Input Carrier Assembly 4 Valve Channel Plate 5 - Output Carrier Assembly 6 - Park Gear 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Drive Link Assembly 9 - Drive Sprocket 10 - Torque Converter Assembly 11 - A/Trans Fluid Pump Assembly 12 - Differential Carrier Assembly 13 - Front Differential Ring Gear 14 - Driven Sprocket 15 - 1-2-3-4 Clutch Assembly 16 - Low and Reverse Clutch Assembly 17 - 2-6 Clutch Assembly 18 - 3-5 Reverse Clutch Assembly 19 - 4-5-6 Clutch Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 3435 20 - A/Trans Input Speed Sensor Assembly 21 - Reaction Sun Gear Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Replacement Transmission Speed Sensor: Service and Repair Output Speed Sensor Replacement Output Speed Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Replacement > Page 3438 Transmission Speed Sensor: Service and Repair Input Speed Sensor Replacement Input Speed Sensor Replacement Removal Procedure 1. Remove the control valve body. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 2. Remove the input speed sensor bolt (2) M6 x 23. 3. Unlock the 2 retaining tabs inside the transmission housing. 4. Remove the input speed sensor (3). 5. Remove the 3 input speed sensor seals (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Replacement > Page 3439 1. Install the 3 input speed sensor seals (1). 2. Install the input speed sensor (3). 3. Verify that the retaining tabs are locked completely. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the input speed sensor bolt (2) M6 x 23 and tighten to 9 Nm (80 lb in). 5. Install the control valve body. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 6. Perform the transmission adaptive values learn procedure. Refer to Transmission Adaptive Values Learn (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations Clutch Pedal Position Sensor / Switch: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations > Page 3444 Clutch Pedal Position Sensor / Switch: Diagrams Component Connector End Views B25B Clutch Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations > Page 3445 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Position Sensor Replacement Removal Procedure 1. Disconnect the clutch pedal position sensor wiring harness plug. 2. Remove the clutch pedal position sensor bolt (2). 3. Remove the clutch pedal position sensor (1). Installation Procedure 1. Install the clutch pedal position sensor (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the clutch pedal position sensor bolt (2) and tighten to 3 Nm(27 lb in). 3. Connect the clutch pedal position sensor wiring harness plug. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations > Page 3446 4. Learn clutch pedal position sensor, refer to Clutch Pedal Position Sensor Learn (See: Transmission and Drivetrain/Manual Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations PROM - Programmable Read Only Memory: Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 3451 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 3452 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Engine/Transmission - Aftermarket Calibrations > Page 3453 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Shift Interlock Solenoid: Diagrams Component Connector End Views S3 Automatic Transmission Shift Lever (MH8) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 3460 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure Note: The automatic transmission shift lock control actuator is part of the automatic transmission control and cannot be removed separately. Remove the shift lock control actuator. Refer to Transmission Control Replacement (See: Automatic Transmission/Transaxle/Shifter A/T/Service and Repair/Transmission Control Replacement). Installation Procedure Install the shift lock control actuator. Refer to Transmission Control Replacement (See: Automatic Transmission/Transaxle/Shifter A/T/Service and Repair/Transmission Control Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Shift Solenoid Valve State and Gear Ratio Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 3464 Shift Solenoid: Service and Repair Control Solenoid Valve and Transmission Control Module Assembly Replacement Removal Procedure 1. Remove the transmission control valve body cover. Refer to Control Valve Body Cover Replacement (LDE, LUW) (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement)Control Valve Body Cover Replacement (LLU, LUJ) (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement). 2. Disconnect the output speed sensor electrical connector (2). 3. Disconnect the shift position switch electrical connector (3). 4. Disconnect the input speed sensor electrical connector (1). 5. Remove the 3 control valve body bolts (1) M5 x 40.5. 6. Remove the 12 control valve body bolts (2) M6 x 97. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 3465 7. Remove the control solenoid valve assembly (3) with transmission control module. Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 8. Remove the control solenoid valve assembly filter plate (4). Discard the filter plate. It is not reusable. 9. Inspect the pressure switch seals for damage or contamination. Replace the control solenoid valve assembly as necessary. 10. Inspect the channel plate bolt pass through holes for damage or burnelling. Any damage could cause leaking. Replace as necessary. Installation Procedure Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 1. Install a NEW control solenoid valve assembly filter plate (4) to prevent fluid leaks past the fluid seals. 2. Install the control solenoid valve assembly (3) with transmission control module. 3. Hand start the control valve body bolts (1, 2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 3466 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Secure the 12 control valve body bolts (2) M6 x 97 and tighten in sequence to 12 Nm(106 lb in). 5. Secure the 3 control valve body bolts (1) M5 x 40.5 and tighten in sequence to 8 Nm(71 lb in). 6. Connect the input speed sensor electrical connector (1). 7. Connect the output speed sensor electrical connector (2). 8. Install the transmission control valve body cover. Refer to Control Valve Body Cover Replacement (LDE, LUW) (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement)Control Valve Body Cover Replacement (LLU, LUJ) (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement). 9. After repairs, refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for programming and set up procedures. 10. Perform the transmission adaptive values learn. Refer to Transmission Adaptive Values Learn (See: Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Shift Interlock Solenoid: Diagrams Component Connector End Views S3 Automatic Transmission Shift Lever (MH8) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 3472 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure Note: The automatic transmission shift lock control actuator is part of the automatic transmission control and cannot be removed separately. Remove the shift lock control actuator. Refer to Transmission Control Replacement (See: Shifter A/T/Service and Repair/Transmission Control Replacement). Installation Procedure Install the shift lock control actuator. Refer to Transmission Control Replacement (See: Shifter A/T/Service and Repair/Transmission Control Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Shift Solenoid Valve State and Gear Ratio Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 3476 Shift Solenoid: Service and Repair Control Solenoid Valve and Transmission Control Module Assembly Replacement Removal Procedure 1. Remove the transmission control valve body cover. Refer to Control Valve Body Cover Replacement (LDE, LUW) (See: Valve Body/Service and Repair/Control Valve Body Cover Replacement)Control Valve Body Cover Replacement (LLU, LUJ) (See: Valve Body/Service and Repair/Control Valve Body Cover Replacement). 2. Disconnect the output speed sensor electrical connector (2). 3. Disconnect the shift position switch electrical connector (3). 4. Disconnect the input speed sensor electrical connector (1). 5. Remove the 3 control valve body bolts (1) M5 x 40.5. 6. Remove the 12 control valve body bolts (2) M6 x 97. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 3477 7. Remove the control solenoid valve assembly (3) with transmission control module. Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 8. Remove the control solenoid valve assembly filter plate (4). Discard the filter plate. It is not reusable. 9. Inspect the pressure switch seals for damage or contamination. Replace the control solenoid valve assembly as necessary. 10. Inspect the channel plate bolt pass through holes for damage or burnelling. Any damage could cause leaking. Replace as necessary. Installation Procedure Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 1. Install a NEW control solenoid valve assembly filter plate (4) to prevent fluid leaks past the fluid seals. 2. Install the control solenoid valve assembly (3) with transmission control module. 3. Hand start the control valve body bolts (1, 2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 3478 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Secure the 12 control valve body bolts (2) M6 x 97 and tighten in sequence to 12 Nm(106 lb in). 5. Secure the 3 control valve body bolts (1) M5 x 40.5 and tighten in sequence to 8 Nm(71 lb in). 6. Connect the input speed sensor electrical connector (1). 7. Connect the output speed sensor electrical connector (2). 8. Install the transmission control valve body cover. Refer to Control Valve Body Cover Replacement (LDE, LUW) (See: Valve Body/Service and Repair/Control Valve Body Cover Replacement)Control Valve Body Cover Replacement (LLU, LUJ) (See: Valve Body/Service and Repair/Control Valve Body Cover Replacement). 9. After repairs, refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for programming and set up procedures. 10. Perform the transmission adaptive values learn. Refer to Transmission Adaptive Values Learn (See: Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Recalls for Control Module: > 10399A > Dec > 10 > Campaign Thermostat Sticks Open Causes Shift Issues Control Module: Recalls Campaign - Thermostat Sticks Open Causes Shift Issues SERVICE UPDATE Bulletin No.: 10399A Date: December 02, 2010 Subject: 10399A - Service Update for Inventory and Customer Vehicles - Powertrain Improvements - Thermostat Sticks in Open Position and Shift Quality - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with a 1.4L Turbo Engine (LUJ) Supercede: The Subject and Purpose in this bulletin are being revised to advise that the new ECM calibration will also address shift quality issues.Please discard all copies of bulletin 10399, issued November 2010. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to reprogram the engine control module (ECM) on certain 2011 model year Chevrolet Cruze vehicles equipped with a 1.4L turbo engine (LUJ). These vehicles may have a condition where the thermostat sticks in the open position. If this occurs, diagnostic codes will be set and the Service Vehicle Soon light/message will illuminate. These vehicles may also have transmission shift quality issues due to calibration values. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. Additionally, a list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should also be checked for vehicle eligibility. Parts Information No parts are required for this update. Service Procedure Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 11/29/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming. 2. Reprogram the engine control module (ECM) and transmission control module (TCM) in sequence. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI or Tech 2(R) to the vehicle. If using MDI, connect to programming terminal with the cable (USB or LAN). 2. Select J-2534 MDI or J-2534 Tech 2(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Recalls for Control Module: > 10399A > Dec > 10 > Campaign Thermostat Sticks Open Causes Shift Issues > Page 3487 3. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. 4. Follow the on-screen instructions. 3. Clear all DTCs using the GDS or Tech 2(R). Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues Control Module: All Technical Service Bulletins Campaign - Thermostat Sticks Open Causes Shift Issues SERVICE UPDATE Bulletin No.: 10399A Date: December 02, 2010 Subject: 10399A - Service Update for Inventory and Customer Vehicles - Powertrain Improvements - Thermostat Sticks in Open Position and Shift Quality - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with a 1.4L Turbo Engine (LUJ) Supercede: The Subject and Purpose in this bulletin are being revised to advise that the new ECM calibration will also address shift quality issues.Please discard all copies of bulletin 10399, issued November 2010. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to reprogram the engine control module (ECM) on certain 2011 model year Chevrolet Cruze vehicles equipped with a 1.4L turbo engine (LUJ). These vehicles may have a condition where the thermostat sticks in the open position. If this occurs, diagnostic codes will be set and the Service Vehicle Soon light/message will illuminate. These vehicles may also have transmission shift quality issues due to calibration values. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. Additionally, a list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should also be checked for vehicle eligibility. Parts Information No parts are required for this update. Service Procedure Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 11/29/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming. 2. Reprogram the engine control module (ECM) and transmission control module (TCM) in sequence. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI or Tech 2(R) to the vehicle. If using MDI, connect to programming terminal with the cable (USB or LAN). 2. Select J-2534 MDI or J-2534 Tech 2(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues > Page 3493 3. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. 4. Follow the on-screen instructions. 3. Clear all DTCs using the GDS or Tech 2(R). Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3494 Control Module: Locations Powertrain Component Views Transmission Components (MH8) 1 - T12 Automatic Transmission Assembly 2 - X1 Transmission Control Module X1 3 - T12 Automatic Transmission Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Water Or Coolant Contamination Information Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Water Or Coolant Contamination Information > Page 3499 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Fluid Capacity Specifications (6T40/45/50) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 3502 Fluid - A/T: Fluid Type Specifications Automatic Transmission DEXRON-VI Automatic Transmission Fluid. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 3503 Fluid - A/T: Service Precautions Checking Hot Transmission Fluid through Drain Plug Hole Warning Warning The engine must be running when the transmission fluid fill plug is removed, or excessive fluid loss will occur. Transmission fluid may be hot. Since the actual fluid level is unknown, stand clear when removing the fill plug. Have a container ready to capture any lost fluid. Do not turn the engine off with the fill plug removed, as you can be injured by hot transmission fluid being expelled out of the oil fill opening. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 3504 Fluid - A/T: Service and Repair Transmission Fluid Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the front compartment insulator. Refer to Front Compartment Insulator Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Insulator Replacement). 3. Remove the fluid level drain plug (1). 4. Drain transmission fluid into a suitable container. Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). 5. Install the fluid level drain plug (1) and tighten to 12 Nm (106 lb in). 6. Install the front compartment insulator. Refer to Front Compartment Insulator Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Insulator Replacement). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 3505 1. Lower the vehicle. 2. Remove the battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). 3. Remove the transmission vent hose (2). 4. Remove the fluid filler cap (1). 5. Fill the transmission to the proper level with the correct fluid. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Level and Condition Check) and Fluid Capacity Specifications (6T40/45/50) (See: Specifications/Capacity Specifications). 6. Install the fluid filler cap (1). 7. Install the transmission vent hose (2). 8. Install the battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hose/Pipe Replacement Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Remove battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 4. Remove the fluid level drain plug (1). 5. Drain transmission fluid into a suitable container. 6. Disconnect transmission fluid cooler pipe (2) from transmission fluid auxiliary cooler and radiator. Remove 2 retainers (1). Refer to Transmission Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 3510 Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection). 7. Remove transmission fluid cooler pipe (2). Installation Procedure 1. Install transmission fluid cooler pipe (2). Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). 2. Connect transmission fluid cooler pipe (2) to transmission fluid auxiliary cooler and radiator. Install 2 retainers (1). Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the fluid level drain plug (1) and tighten to 12 Nm (106 lb in) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 3511 4. Top up transmission fluid and check transmission fluid level. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Level and Condition Check). 5. Install front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 6. Install battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 3512 Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Inlet Pipe Replacement Transmission Fluid Cooler Inlet Pipe Replacement (LLU, LUJ) (1.4L) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 3513 Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Pipe Connector Replacement Radiator Transmission Fluid Cooler Pipe Connector Replacement - Radiator (LLU, LUJ) (1.4L) Removal Procedure 1. Remove charge air cooler outlet air hose. Refer to Charge Air Cooler Outlet Air Hose Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair). 2. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). 3. Remove the fluid level drain plug (1). 4. Drain transmission fluid into a suitable container. 5. Remove the transmission oil cooler pipes from the oil cooler fittings on the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 3514 Note: Do not remove the upper and lower transmission oil cooler fittings from the radiator at the same time other wise the transmission oil cooler will fall inside the radiator end tank. 6. Remove the oil cooler fitting (1) and the O-ring (2) from the radiator. Installation Procedure 1. Inspect the NEW O-ring (2) seals for cracks, cuts or damage. Replace if necessary. Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). Note: The correct thread engagement is critical. Cross-threaded fittings can achieve proper tightness and still leak. 2. Install the oil cooler fitting (1) to the radiator and tighten to 20 Nm (15 lb ft). 3. Install the transmission oil cooler hoses to the oil cooler fittings to the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection). 4. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Engine, Cooling and Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 3515 Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). Caution: Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 5. Install the fluid level drain plug (1) and tighten to 12 Nm (106 lb in) 6. Top up transmission fluid and check transmission fluid level. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Level and Condition Check). 7. Install charge air cooler outlet air hose. Refer to Charge Air Cooler Outlet Air Hose Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair). 8. Inspect for fluid leaks. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 3516 Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Removal Procedure Note: Perform the following procedure when removing the retaining rings and cooler lines from the quick connect fittings located on the radiator and/or the transmission. 1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 in). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring (1) in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring. 5. Pull the cooler line (1) straight out from the quick connect fitting (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 3517 Installation Procedure Note: * Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. * Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install new retaining rings. * Ensure the following procedures are performed when installing the new retaining rings onto the fittings. 1. Install a new retaining ring into the quick connect fitting using the following procedure: 2. Hook one of the open ends of the retaining ring (1) in one of the slots in the quick connect fitting. 3. Rotate the retaining ring (1) around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 3518 4. Do not install the new retaining ring (1) onto the fitting by pushing the retaining ring. 5. Ensure that the three retaining ring ears are seen from inside the fitting (1) and that the retaining ring moves freely in the fitting slots. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 3519 6. Install the cooler line (1) into the quick connect fitting (2). 7. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 8. Do not use the plastic cap (1) on the cooler line in order to install the cooler line into the fitting. 9. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 3520 Note: Do not manually depress the retaining clip when installing the plastic cap. 10. Position (snap) the plastic cap (1) onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 11. Ensure that the plastic cap is fully seated against the fitting. 12. Ensure that no gap is present between the plastic cap (1) and the fitting (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 3521 13. Ensure that the yellow identification band (1) on the tube is hidden within the quick connect fitting. 14. A hidden yellow identification band (1) indicates proper joint seating. 15. Fill the transmission to the proper level. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Level and Condition Check). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 3522 Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Outlet Pipe Replacement Transmission Fluid Cooler Outlet Pipe Replacement (LLU, LUJ) (1.4L) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Control valve body cover bolts ............................................................................................................ ...................................................... 12 Nm (106 lb in) Tighten the bolts in sequence Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair Automatic or Manual Transmission Control Lever Trim Cover Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Recalls for Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues Control Module: Recalls Campaign - Thermostat Sticks Open Causes Shift Issues SERVICE UPDATE Bulletin No.: 10399A Date: December 02, 2010 Subject: 10399A - Service Update for Inventory and Customer Vehicles - Powertrain Improvements - Thermostat Sticks in Open Position and Shift Quality - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with a 1.4L Turbo Engine (LUJ) Supercede: The Subject and Purpose in this bulletin are being revised to advise that the new ECM calibration will also address shift quality issues.Please discard all copies of bulletin 10399, issued November 2010. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to reprogram the engine control module (ECM) on certain 2011 model year Chevrolet Cruze vehicles equipped with a 1.4L turbo engine (LUJ). These vehicles may have a condition where the thermostat sticks in the open position. If this occurs, diagnostic codes will be set and the Service Vehicle Soon light/message will illuminate. These vehicles may also have transmission shift quality issues due to calibration values. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. Additionally, a list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should also be checked for vehicle eligibility. Parts Information No parts are required for this update. Service Procedure Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 11/29/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming. 2. Reprogram the engine control module (ECM) and transmission control module (TCM) in sequence. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI or Tech 2(R) to the vehicle. If using MDI, connect to programming terminal with the cable (USB or LAN). 2. Select J-2534 MDI or J-2534 Tech 2(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Recalls for Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues > Page 3539 3. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. 4. Follow the on-screen instructions. 3. Clear all DTCs using the GDS or Tech 2(R). Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues Control Module: All Technical Service Bulletins Campaign - Thermostat Sticks Open Causes Shift Issues SERVICE UPDATE Bulletin No.: 10399A Date: December 02, 2010 Subject: 10399A - Service Update for Inventory and Customer Vehicles - Powertrain Improvements - Thermostat Sticks in Open Position and Shift Quality - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with a 1.4L Turbo Engine (LUJ) Supercede: The Subject and Purpose in this bulletin are being revised to advise that the new ECM calibration will also address shift quality issues.Please discard all copies of bulletin 10399, issued November 2010. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to reprogram the engine control module (ECM) on certain 2011 model year Chevrolet Cruze vehicles equipped with a 1.4L turbo engine (LUJ). These vehicles may have a condition where the thermostat sticks in the open position. If this occurs, diagnostic codes will be set and the Service Vehicle Soon light/message will illuminate. These vehicles may also have transmission shift quality issues due to calibration values. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. Additionally, a list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should also be checked for vehicle eligibility. Parts Information No parts are required for this update. Service Procedure Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 11/29/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming. 2. Reprogram the engine control module (ECM) and transmission control module (TCM) in sequence. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI or Tech 2(R) to the vehicle. If using MDI, connect to programming terminal with the cable (USB or LAN). 2. Select J-2534 MDI or J-2534 Tech 2(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues > Page 3545 3. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. 4. Follow the on-screen instructions. 3. Clear all DTCs using the GDS or Tech 2(R). Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3546 Control Module: Locations Powertrain Component Views Transmission Components (MH8) 1 - T12 Automatic Transmission Assembly 2 - X1 Transmission Control Module X1 3 - T12 Automatic Transmission Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Front Wheel Drive Shaft Seal Replacement - Left Side Seals and Gaskets: Service and Repair Front Wheel Drive Shaft Seal Replacement - Left Side Front Wheel Drive Shaft Seal Replacement - Left Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Front Wheel Drive Shaft Seal Replacement - Left Side > Page 3551 Seals and Gaskets: Service and Repair Front Wheel Drive Shaft Seal Replacement - Right Side Front Wheel Drive Shaft Seal Replacement - Right Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Front Wheel Drive Shaft Seal Replacement - Left Side > Page 3552 Seals and Gaskets: Service and Repair Manual Shift Shaft and Seal Replacement Manual Shift Shaft and Seal Replacement Special Tools * DT-45201 - Cooler Line Seal Remover * DT-49101 - Seal Installer For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Remove the battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). 2. Remove the manual shaft and position switch assembly. Refer to Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement ( See: Sensors and Switches - A/T/Transmission Position Switch/Sensor/Service and Repair). 3. Remove the manual shaft seal (1) using DT-45201 - seal remover. Installation Procedure 1. Install the manual shaft and position switch assembly. Refer to Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement ( See: Sensors and Switches - A/T/Transmission Position Switch/Sensor/Service and Repair) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Front Wheel Drive Shaft Seal Replacement - Left Side > Page 3553 2. Install the manual shaft seal (1) using DT-49101 - seal installer. 3. Install the battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair Transmission Position Switch/Sensor: Service and Repair Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Special Tools DT-41229 - Manual Shaft Pin Installer For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Remove the control valve body. Refer to Control Valve Body Replacement (See: Valve Body/Service and Repair/Control Valve Body Replacement). 2. Remove the manual shaft detent lever hub pin (1) using a pry bar and pliers. 3. Remove and DISCARD the manual shift shaft pin (5). 4. Remove the manual shaft (2). 5. Disconnect the actuator rod (3) from the detent lever assembly. Do not remove the actuator rod from the transmission case. 6. Remove the manual shaft detent (with shift position switch) lever assembly (4). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Page 3558 1. Connect the actuator rod (3) to the detent lever assembly. 2. Install the manual shaft detent (with shift position switch) lever assembly (4). 3. Install the manual shaft (2). 4. Install the manual shaft detent lever hub pin (1) to height of 7.9 mm (0.38 in) (b). Caution: Use J 41229 to install the manual shaft pin at the correct height in order to properly secure the manual shaft. If you install the pin too deep, the case bore may crack. 5. Install the NEW manual shift shaft pin (5) using DT-41229 - pin installer. Use a NEW pin to ensure proper engagement with the case. 6. Inspect pin installed height is within 7.2-8.2 mm (0.28-0.32 in) (a). 7. Install the control valve body. Refer to Control Valve Body Replacement (See: Valve Body/Service and Repair/Control Valve Body Replacement). 8. Perform the transmission adaptive values learn procedure. Refer to Transmission Adaptive Values Learn (See: Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations Transmission Speed Sensor: Locations Component Location 1 - Reaction Carrier Assembly 2 - Control Valve Body Assembly 3 - Input Carrier Assembly 4 Valve Channel Plate 5 - Output Carrier Assembly 6 - Park Gear 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Drive Link Assembly 9 - Drive Sprocket 10 - Torque Converter Assembly 11 - A/Trans Fluid Pump Assembly 12 - Differential Carrier Assembly 13 - Front Differential Ring Gear 14 - Driven Sprocket 15 - 1-2-3-4 Clutch Assembly 16 - Low and Reverse Clutch Assembly 17 - 2-6 Clutch Assembly 18 - 3-5 Reverse Clutch Assembly 19 - 4-5-6 Clutch Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 3562 20 - A/Trans Input Speed Sensor Assembly 21 - Reaction Sun Gear Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Replacement Transmission Speed Sensor: Service and Repair Output Speed Sensor Replacement Output Speed Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Replacement > Page 3565 Transmission Speed Sensor: Service and Repair Input Speed Sensor Replacement Input Speed Sensor Replacement Removal Procedure 1. Remove the control valve body. Refer to Control Valve Body Replacement (See: Valve Body/Service and Repair/Control Valve Body Replacement). 2. Remove the input speed sensor bolt (2) M6 x 23. 3. Unlock the 2 retaining tabs inside the transmission housing. 4. Remove the input speed sensor (3). 5. Remove the 3 input speed sensor seals (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Replacement > Page 3566 1. Install the 3 input speed sensor seals (1). 2. Install the input speed sensor (3). 3. Verify that the retaining tabs are locked completely. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the input speed sensor bolt (2) M6 x 23 and tighten to 9 Nm (80 lb in). 5. Install the control valve body. Refer to Control Valve Body Replacement (See: Valve Body/Service and Repair/Control Valve Body Replacement). 6. Perform the transmission adaptive values learn procedure. Refer to Transmission Adaptive Values Learn (See: Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Diagrams Shift Interlock Solenoid: Diagrams Component Connector End Views S3 Automatic Transmission Shift Lever (MH8) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 3571 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure Note: The automatic transmission shift lock control actuator is part of the automatic transmission control and cannot be removed separately. Remove the shift lock control actuator. Refer to Transmission Control Replacement (See: Shifter A/T/Service and Repair/Transmission Control Replacement). Installation Procedure Install the shift lock control actuator. Refer to Transmission Control Replacement (See: Shifter A/T/Service and Repair/Transmission Control Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Shift Solenoid Valve State and Gear Ratio Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 3575 Shift Solenoid: Service and Repair Control Solenoid Valve and Transmission Control Module Assembly Replacement Removal Procedure 1. Remove the transmission control valve body cover. Refer to Control Valve Body Cover Replacement (LDE, LUW) (See: Valve Body/Service and Repair/Control Valve Body Cover Replacement)Control Valve Body Cover Replacement (LLU, LUJ) (See: Valve Body/Service and Repair/Control Valve Body Cover Replacement). 2. Disconnect the output speed sensor electrical connector (2). 3. Disconnect the shift position switch electrical connector (3). 4. Disconnect the input speed sensor electrical connector (1). 5. Remove the 3 control valve body bolts (1) M5 x 40.5. 6. Remove the 12 control valve body bolts (2) M6 x 97. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 3576 7. Remove the control solenoid valve assembly (3) with transmission control module. Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 8. Remove the control solenoid valve assembly filter plate (4). Discard the filter plate. It is not reusable. 9. Inspect the pressure switch seals for damage or contamination. Replace the control solenoid valve assembly as necessary. 10. Inspect the channel plate bolt pass through holes for damage or burnelling. Any damage could cause leaking. Replace as necessary. Installation Procedure Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 1. Install a NEW control solenoid valve assembly filter plate (4) to prevent fluid leaks past the fluid seals. 2. Install the control solenoid valve assembly (3) with transmission control module. 3. Hand start the control valve body bolts (1, 2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 3577 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Secure the 12 control valve body bolts (2) M6 x 97 and tighten in sequence to 12 Nm(106 lb in). 5. Secure the 3 control valve body bolts (1) M5 x 40.5 and tighten in sequence to 8 Nm(71 lb in). 6. Connect the input speed sensor electrical connector (1). 7. Connect the output speed sensor electrical connector (2). 8. Install the transmission control valve body cover. Refer to Control Valve Body Cover Replacement (LDE, LUW) (See: Valve Body/Service and Repair/Control Valve Body Cover Replacement)Control Valve Body Cover Replacement (LLU, LUJ) (See: Valve Body/Service and Repair/Control Valve Body Cover Replacement). 9. After repairs, refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for programming and set up procedures. 10. Perform the transmission adaptive values learn. Refer to Transmission Adaptive Values Learn (See: Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Transmission Control Lever Knob Replacement Shifter A/T: Service and Repair Transmission Control Lever Knob Replacement Transmission Control Lever Knob Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Transmission Control Lever Knob Replacement > Page 3582 Shifter A/T: Service and Repair Transmission Control Replacement Transmission Control Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Transmission Control Lever Knob Replacement > Page 3583 Shifter A/T: Service and Repair Automatic Transmission Range Selector Lever Replacement Automatic Transmission Range Selector Lever Replacement Removal Procedure 1. Set the park brake and chock the wheels. 2. Remove the battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). 3. Disconnect the transmission range selector lever cable terminal (1) from the transmission manual shift lever pin. 4. Press the locking tabs inward in order to release the transmission range selector lever cable (2) from the cable bracket. Warning Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Transmission Control Lever Knob Replacement > Page 3584 Hold the transmission range selector lever while removing or installing the lever retaining nut. Excessive torque on the manual shaft can damage the detent lever hub retainer which could allow the vehicle to roll when placed in the park position. 5. Remove the transmission range selector lever nut (1). 6. Remove the transmission range selector lever (2). Installation Procedure Warning Hold the transmission range selector lever while removing or installing the lever retaining nut. Excessive torque on the manual shaft can damage the detent lever hub retainer which could allow the vehicle to roll when placed in the park position. 1. Install the transmission range selector lever (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the transmission range selector lever nut (1) and tighten to 30 Nm (22 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Transmission Control Lever Knob Replacement > Page 3585 3. Install the transmission range selector lever cable (2) to the cable bracket. 4. Connect the transmission range selector lever cable terminal (1) to the transmission manual shift lever pin. 5. Check the range selector cable adjustment. Refer to Range Selector Lever Cable Adjustment (See: Shift Linkage/Shift Cable/Adjustments). 6. Install the battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments Shift Cable: Adjustments Range Selector Lever Cable Adjustment Removal Procedure Note: Adjust the automatic transmission range selector cable while the transmission and the gear selector are in the Park position only. Failure to do so may cause miss-adjustment. 1. Set the park brake and chock the wheels. 2. Remove transmission control lever trim cover. Refer to Automatic or Manual Transmission Control Lever Trim Cover Replacement (See: Lamps and Indicators - A/T/Shift Indicator/Service and Repair) 3. Remove instrument panel center compartment mat. 4. Remove front floor console storage tray. Refer to Front Floor Console Storage Tray Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Storage Tray Replacement) 5. Remove range selector lever cable adjust lock (1). 6. Remove engine control module from battery tray. Refer to Engine Control Module Replacement (See: Powertrain Management/Computers and Control Systems/Engine Control Module/Service and Repair) Installation Procedure 1. Verify the transmission range selector lever is in the park position. 2. Verify the transmission shift lever is in the park position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 3590 3. Install the range selector lever cable adjust lock (1). 4. Install front floor console storage tray. Refer to Front Floor Console Storage Tray Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Storage Tray Replacement) 5. Install instrument panel center compartment mat. 6. Install transmission control lever trim cover. Refer to Automatic or Manual Transmission Control Lever Trim Cover Replacement (See: Lamps and Indicators - A/T/Shift Indicator/Service and Repair) 7. Install engine control module to battery tray. Refer to Engine Control Module Replacement (See: Powertrain Management/Computers and Control Systems/Engine Control Module/Service and Repair) 8. Check the transmission range selector lever in all gear selections for proper operation. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement Shift Cable: Service and Repair Range Selector Lever Cable Replacement Range Selector Lever Cable Replacement Removal Procedure 1. Set the park brake and chock the wheels. 2. Disconnect the transmission range selector lever cable (1) from the transmission manual shift lever pin and cable bracket. 3. Remove the front floor console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). 4. Remove the transmission range selector lever cable (1) from the cable bracket (3). 5. Remove the cable end terminal from shifter pin (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 3593 6. Remove the transmission range selector lever cable grommet (1) from the cowl panel. 7. Remove the transmission range selector lever cable from the vehicle. Installation Procedure 1. Install the transmission range selector lever cable to the vehicle. 2. Install the transmission range selector lever cable grommet (1) to the cowl panel. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 3594 3. Connect the transmission range selector cable terminal to the shift lever pin (2). 4. Install the transmission range selector lever cable (1) to the cable bracket (3) 5. Install the front floor console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). 6. Connect the transmission range selector lever cable (1) to the transmission manual shift lever pin and cable bracket. 7. Adjust the range selector lever cable. Refer to Range Selector Lever Cable Adjustment (See: Adjustments). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 3595 Shift Cable: Service and Repair Range Selector Lever Cable Bracket Replacement Range Selector Lever Cable Bracket Replacement Removal Procedure 1. Set the park brake and chock the wheels. 2. Remove the battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). 3. Disconnect the range selector cable end (1) from the range selector lever. 4. Disconnect the range selector cable (2) from the range selector cable bracket. 5. Remove the transmission range selector cable bracket bolts (1). 6. Remove the transmission range selector cable bracket (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 3596 Installation Procedure 1. Install the transmission range selector cable bracket (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the transmission range selector cable bracket bolts (1, 2) and tighten to 22 Nm (16 lb ft). 3. Connect the range selector cable (2) to the range selector cable bracket. 4. Connect the range selector cable end (1) to the range selector lever. 5. Check the range selector cable adjustment. Refer to Range Selector Lever Cable Adjustment (See: Adjustments). 6. Install the battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 3601 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 3602 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 3603 Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 3604 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 3605 Transmission Cooler: Service and Repair Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove radiator grille reinforcement support. Refer to Radiator Grille Reinforcement Support Replacement (See: Body and Frame/Radiator Support/Service and Repair/Radiator Grille Reinforcement Support Replacement). 2. Remove the fluid level drain plug (1). 3. Drain transmission fluid into a suitable container. 4. Detach transmission fluid cooler outlet pipe (3) and transmission fluid cooler intermediate pipe (4) from transmission fluid auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Fluid Line/Hose/Service and Repair/Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection). 5. Remove transmission fluid auxiliary cooler pipe bolt (5). 6. Remove radiator air seal (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 3606 7. Remove transmission fluid auxiliary cooler (2). Installation Procedure 1. Install transmission fluid auxiliary cooler (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install transmission fluid auxiliary cooler pipe bolt (5) and tighten to 4 Nm (35 lb in). 3. Attach transmission fluid cooler intermediate pipe (4) and fluid cooler outlet pipe (3) to transmission fluid auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Fluid Line/Hose/Service and Repair/Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection). 4. Install radiator air seal (1). 5. Install the fluid level drain plug (1) and tighten to 12 Nm (106 lb in) 6. Top up transmission fluid and check transmission fluid level. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Level and Condition Check). 7. Install radiator grille reinforcement support. Refer to Radiator Grille Reinforcement Support Replacement (See: Body and Frame/Radiator Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 3607 Support/Service and Repair/Radiator Grille Reinforcement Support Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Bracket Replacement - Rear Transmission Mount: Service and Repair Transmission Mount Bracket Replacement - Rear Transmission Mount Bracket Replacement - Rear Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Using a suitable jack stand, support the rear of the transmission. 3. Remove the rear transmission mount bracket to rear mount through bolt (1). 4. Remove the 3 rear transmission mount bracket to transmission bolts (1). 5. Remove the rear transmission mount bracket (2). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Bracket Replacement - Rear > Page 3612 1. Install the rear transmission mount bracket (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 rear transmission mount bracket to transmission bolts (1) and tighten to 100 Nm (74 lb ft). 3. Install the rear transmission mount bracket to rear mount through bolt (1) and tighten to 100 Nm (74 lb ft). 4. Remove the jack stand. 5. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Bracket Replacement - Rear > Page 3613 Transmission Mount: Service and Repair Transmission Mount Replacement - Left Side Transmission Mount Replacement - Left Side Removal Procedure 1. Remove the battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Splash Shield Replacement). 4. Install the engine support fixture. For the 1.4L engine, refer to Engine Support Fixture (See: Engine, Cooling and Exhaust/Engine/Service and Repair/Overhaul/1. Engine Support Fixture). For the 1.8L engine, refer to Engine Support Fixture (See: Engine, Cooling and Exhaust/Engine/Service and Repair/Overhaul/1. Engine Support Fixture). 5. Lower the vehicle. 6. Remove and DISCARD the left transmission mount to bracket bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Bracket Replacement - Rear > Page 3614 7. Remove the left transmission mount to body bolts (1). 8. Remove the left transmission mount to body nut (2). 9. Remove the transmission mount (3) from the vehicle. Installation Procedure 1. Install the left transmission mount (3) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the transmission mount to body bolts (1) and tighten to 62 Nm (46 lb ft). 3. Install the transmission mount to body nut (2) and tighten to 62 Nm (46 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Bracket Replacement - Rear > Page 3615 4. Install the NEW left transmission mount to transmission bolts (1) and tighten to 50 Nm + 60°-75° (37 lb ft + 60°-75°). 5. Raise the vehicle. 6. Remove the engine support fixture. 7. Install the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Splash Shield Replacement). 8. Lower the vehicle. 9. Install the battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Bracket Replacement - Rear > Page 3616 Transmission Mount: Service and Repair Transmission Front Mount Replacement Transmission Front Mount Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Support the front of the transmission using a suitable jack stand. 3. Remove the transmission front mount through bolt (1). 4. Remove the transmission front mount bolts (1). 5. Remove the transmission front mount (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Bracket Replacement - Rear > Page 3617 1. Install the transmission front mount (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the transmission front mount bolts (1) and tighten to 62 Nm (46 lb ft). 3. Install the transmission front mount through bolt (1) and tighten to 100 Nm (74 lb ft). 4. Remove the jack stand. 5. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Bracket Replacement - Rear > Page 3618 Transmission Mount: Service and Repair Transmission Rear Mount Replacement Transmission Rear Mount Replacement Removal Procedure 1. Remove steering gear - EPS. Refer to Steering Gear Replacement (See: Steering and Suspension/Steering/Steering Gear/Service and Repair/Steering Gear Replacement). 2. Remove rear transmission mount bracket. Refer to Transmission Mount Bracket Replacement Rear (See: Transmission Mount Bracket Replacement - Rear). 3. Remove rear transmission mount to frame bolts (1) and nuts (2). 4. Remove rear transmission mount. Installation Procedure 1. Install rear transmission mount. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Bracket Replacement - Rear > Page 3619 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install rear transmission mount to frame bolts (1) and nuts (2) and tighten to 110 Nm (81 lb ft). 3. Install rear transmission mount bracket. Refer to Transmission Mount Bracket Replacement - Rear (See: Transmission Mount Bracket Replacement - Rear). 4. Install steering gear - EPS. Refer to Steering Gear Replacement (See: Steering and Suspension/Steering/Steering Gear/Service and Repair/Steering Gear Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair Transmission Position Switch/Sensor: Service and Repair Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Special Tools DT-41229 - Manual Shaft Pin Installer For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Remove the control valve body. Refer to Control Valve Body Replacement (See: Valve Body/Service and Repair/Control Valve Body Replacement). 2. Remove the manual shaft detent lever hub pin (1) using a pry bar and pliers. 3. Remove and DISCARD the manual shift shaft pin (5). 4. Remove the manual shaft (2). 5. Disconnect the actuator rod (3) from the detent lever assembly. Do not remove the actuator rod from the transmission case. 6. Remove the manual shaft detent (with shift position switch) lever assembly (4). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Page 3623 1. Connect the actuator rod (3) to the detent lever assembly. 2. Install the manual shaft detent (with shift position switch) lever assembly (4). 3. Install the manual shaft (2). 4. Install the manual shaft detent lever hub pin (1) to height of 7.9 mm (0.38 in) (b). Caution: Use J 41229 to install the manual shaft pin at the correct height in order to properly secure the manual shaft. If you install the pin too deep, the case bore may crack. 5. Install the NEW manual shift shaft pin (5) using DT-41229 - pin installer. Use a NEW pin to ensure proper engagement with the case. 6. Inspect pin installed height is within 7.2-8.2 mm (0.28-0.32 in) (a). 7. Install the control valve body. Refer to Control Valve Body Replacement (See: Valve Body/Service and Repair/Control Valve Body Replacement). 8. Perform the transmission adaptive values learn procedure. Refer to Transmission Adaptive Values Learn (See: Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Service and Repair Transmission Pressure Test Port: Service and Repair Automatic Transmission Fluid Pressure Test Hole Plug Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations Transmission Speed Sensor: Locations Component Location 1 - Reaction Carrier Assembly 2 - Control Valve Body Assembly 3 - Input Carrier Assembly 4 Valve Channel Plate 5 - Output Carrier Assembly 6 - Park Gear 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Drive Link Assembly 9 - Drive Sprocket 10 - Torque Converter Assembly 11 - A/Trans Fluid Pump Assembly 12 - Differential Carrier Assembly 13 - Front Differential Ring Gear 14 - Driven Sprocket 15 - 1-2-3-4 Clutch Assembly 16 - Low and Reverse Clutch Assembly 17 - 2-6 Clutch Assembly 18 - 3-5 Reverse Clutch Assembly 19 - 4-5-6 Clutch Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Page 3630 20 - A/Trans Input Speed Sensor Assembly 21 - Reaction Sun Gear Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Replacement Transmission Speed Sensor: Service and Repair Output Speed Sensor Replacement Output Speed Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Replacement > Page 3633 Transmission Speed Sensor: Service and Repair Input Speed Sensor Replacement Input Speed Sensor Replacement Removal Procedure 1. Remove the control valve body. Refer to Control Valve Body Replacement (See: Valve Body/Service and Repair/Control Valve Body Replacement). 2. Remove the input speed sensor bolt (2) M6 x 23. 3. Unlock the 2 retaining tabs inside the transmission housing. 4. Remove the input speed sensor (3). 5. Remove the 3 input speed sensor seals (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Replacement > Page 3634 1. Install the 3 input speed sensor seals (1). 2. Install the input speed sensor (3). 3. Verify that the retaining tabs are locked completely. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the input speed sensor bolt (2) M6 x 23 and tighten to 9 Nm (80 lb in). 5. Install the control valve body. Refer to Control Valve Body Replacement (See: Valve Body/Service and Repair/Control Valve Body Replacement). 6. Perform the transmission adaptive values learn procedure. Refer to Transmission Adaptive Values Learn (See: Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations Valve Body: Locations Ball Check Valve Locations Disassembled Views (6T40/45) Control Valve Body Assembly (1 of 2) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > Page 3638 400 - Control Valve Body Bolt 401 - Control Solenoid Valve Support 402 - Valve Channel Plate 403 - Channel Plate to Valve Body Spacer Plate Assembly 404 - Control Valve Body Ball Check Valve 405 - Control Valve Body Assembly Control Valve Body Assembly (2 of 2) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > Page 3639 410 - Reverse and 4-5-6 Clutch Regulator Valve Spring 411 - Reverse and 4-5-6 Clutch Regulator Valve 412 - Clutch Valve Bore Plug 413 - Valve Spring Retainer 414 - 1-2-3-4 Clutch Boost Valve 415 - 1-2-3-4 Clutch Boost Valve Spring 416 - 1-2-3-4 Clutch Regulator Valve Spring 417 - 1-2-3-4 Clutch Regulator Valve 418 - 2-6 Clutch Regulator Valve Spring 419 - 2-6 Clutch Regulator Valve 420 - 3-5-Reverse Clutch Regulator Valve Spring 421 - 3-5-Reverse Clutch Regulator Valve 422 Clutch Piston Dam Feed Regulator Valve 423 - Clutch Piston Dam Feed Regulator Valve Spring 424 - Torque Converter Clutch Regulator Apply Valve Spring 425 - Torque Converter Clutch Regulator Apply Valve 426 - Torque Converter Clutch Regulator Apply Shuttle Valve 427 - Clutch Select Valve Spring 428 - Clutch Select Valve 429 - Default Override Shuttle Valve 430 - Actuator Feed Limit Valve 431 - Actuator Feed Limit Valve Spring 432 - Manual Valve 433 - Control Valve Body Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Control Valve Body Cover Replacement Valve Body: Service and Repair Control Valve Body Cover Replacement Control Valve Body Cover Replacement (LLU, LUJ) (1.4L) Removal Procedure 1. Remove the battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove front compartment splash shield. Refer to Front Compartment Splash Shield Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Splash Shield Replacement) 4. Remove the fluid level drain plug (1). 5. Drain transmission fluid into a suitable container. 6. Lower the vehicle. 7. Remove radiator inlet hose. Refer to Radiator Inlet Hose Replacement (LDD, LUH, and LUJ) (See: Engine, Cooling and Exhaust/Cooling System/Radiator Hose/Service and Repair/Radiator Inlet Hose Replacement)Radiator Inlet Hose Replacement (LDE, LXV, 2H0, and LUW) ( See: Engine, Cooling and Exhaust/Cooling System/Radiator Hose/Service and Repair/Radiator Inlet Hose Replacement). 8. Remove charge air cooler outlet air hose. Refer to Charge Air Cooler Outlet Air Hose Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair). 9. Remove transmission fluid cooler inlet pipe. Refer to Transmission Fluid Cooler Inlet Pipe Replacement (LDE, LUW) (See: Fluid Line/Hose/Service and Repair/Transmission Fluid Cooler Inlet Pipe Replacement)Transmission Fluid Cooler Inlet Pipe Replacement (LLU, LUJ) (See: Fluid Line/Hose/Service and Repair/Transmission Fluid Cooler Inlet Pipe Replacement). 10. Discard sealing washer. 11. Remove transmission fluid cooler outlet pipe. Refer to Transmission Fluid Cooler Outlet Pipe Replacement (LDE, LUW) (See: Fluid Line/Hose/Service and Repair/Transmission Fluid Cooler Outlet Pipe Replacement)Transmission Fluid Cooler Outlet Pipe Replacement (LLU, LUJ) (See: Fluid Line/Hose/Service and Repair/Transmission Fluid Cooler Outlet Pipe Replacement). 12. Discard the sealing washer. 13. Plug and/or cap the pipes and transmission to prevent contamination. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Control Valve Body Cover Replacement > Page 3642 14. Disconnect electrical connector (1) transmission control module (TCM), then unclip the connector from the transmission. 15. Remove wiring harness starter motor from transmission. Remove bolt from retainer on valve body cover. Unclip wiring harness from retainer on valve body cover and range selector cable bracket. 16. Remove the control valve body cover bolts (1). 17. Remove the control valve body cover (2). 18. Remove the control valve body cover gasket (3). Caution: Support the control solenoid valve assembly around the connector when removing the seal. Excessive pulling force can damage the internal electrical connections. 19. Remove the control valve body cover wiring connector hole seal (4). 20. Remove all traces of the old gasket material. Clean the transmission case and control valve body cover gasket surfaces. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Control Valve Body Cover Replacement > Page 3643 1. Install the control valve body cover wiring connector hole seal (4). 2. Install the control valve body cover gasket (3) to the control valve body cover. 3. Install the control valve body cover (2). 4. Hand start the control valve body cover bolts (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Install all control valve body cover bolts and studs by hand then torque all bolts and studs in sequence. 5. Install the control valve body cover bolts. Tighten the bolts in sequence to 12 Nm (106 lb in). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Control Valve Body Cover Replacement > Page 3644 6. Connect the electrical connector (1) transmission control module (TCM), then clip in the wiring harness to transmission. 7. Install the wiring harness starter motor to transmission. Install bolt to retainer on valve body cover. Clip in wiring harness to retainer on valve body cover and range selector cable bracket. 8. Raise the vehicle. 9. Install the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Splash Shield Replacement) 10. Lower the vehicle. 11. Install the transmission fluid cooler outlet pipe. Use NEW sealing washer. Refer to Transmission Fluid Cooler Outlet Pipe Replacement (LDE, LUW) (See: Fluid Line/Hose/Service and Repair/Transmission Fluid Cooler Outlet Pipe Replacement)Transmission Fluid Cooler Outlet Pipe Replacement (LLU, LUJ) (See: Fluid Line/Hose/Service and Repair/Transmission Fluid Cooler Outlet Pipe Replacement). 12. Install the transmission fluid cooler inlet pipe to the transmission. Use NEW sealing washer. Refer to Transmission Fluid Cooler Inlet Pipe Replacement (LDE, LUW) (See: Fluid Line/Hose/Service and Repair/Transmission Fluid Cooler Inlet Pipe Replacement)Transmission Fluid Cooler Inlet Pipe Replacement (LLU, LUJ) (See: Fluid Line/Hose/Service and Repair/Transmission Fluid Cooler Inlet Pipe Replacement). 13. Install radiator inlet hose. Refer to Radiator Inlet Hose Replacement (LDD, LUH, and LUJ) (See: Engine, Cooling and Exhaust/Cooling System/Radiator Hose/Service and Repair/Radiator Inlet Hose Replacement)Radiator Inlet Hose Replacement (LDE, LXV, 2H0, and LUW) ( See: Engine, Cooling and Exhaust/Cooling System/Radiator Hose/Service and Repair/Radiator Inlet Hose Replacement). 14. Remove charge air cooler outlet air hose. Refer to Charge Air Cooler Outlet Air Hose Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Control Valve Body Cover Replacement > Page 3645 15. Install the fluid level drain plug (1) and tighten to 12 Nm (106 lb in) 16. Top up transmission fluid and check transmission fluid level. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Level and Condition Check). 17. Check for leaks. 18. Install the battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Control Valve Body Cover Replacement > Page 3646 Valve Body: Service and Repair Control Valve Body Replacement Control Valve Body Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Control Valve Body Cover Replacement > Page 3647 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair Clutch Disc: Service and Repair Clutch Pressure and Driven Plate Replacement (LUJ, LUW with MF3, MZ0, or MZ4) (1.4L, 1.8L) Special Tools DT-6263 - Remover / Installer For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure Note: * To prevent damage to the spring tangs of pressure plate use DT-6263 - remover / installer to remove and install clutch pressure plate. * Note the different lengths of the brackets for attaching DT-6263 - remover / installer to lower engine block. 1. Remove transmission. Refer to Transmission Replacement (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement ). Note: DT-6263 - remover / installer may only be attached to the engine block and not to the oil pan. 2. Attach DT-6263 - remover / installer (1) to engine block. Note: Do not tighten the bolts yet. 3. Install 4 bolts (arrows) to engine block. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Page 3652 4. Attach a suitable clutch center guide (5) to DT-6263-30 - centering drift (4). 5. Fasten DT-6263 remover / installer. * Align DT-6263 - remover / installer to center. * Insert DT-6263-30 - centering drift (2) in conjunction with clutch center guide through DT-6263 remover / installer into clutch pressure plate and crankshaft center (arrow). * Tighten knurled wheel (1). * Tighten bolt (3). * Tighten 4 bolts of DT-6263 - remover / installer to the engine block. 6. Preload clutch springs using DT-6263 - remover / installer. * Move DT-6263 - remover / installer (1) that it rests against the spring tangs of clutch pressure plate. * Turn DT-6263 - remover / installer clockwise to the stop. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Page 3653 Note: DISCARD the bolts. 7. Remove 6 clutch pressure plate bolts (1). 8. Release DT-6263 - remover / installer (1). * Turn DT-6263 - remover / installer counterclockwise to the stop. * Remove DT-6263-30 - centering drift (2) in conjunction with clutch center guide. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Page 3654 9. Remove clutch pressure plate (2) and driven plate (1). Note: Clutch pressure plate and driven plates contaminated by foreign bodies (oil, cleaning agent etc.) have to be replaced. Check clutch driven plate for damage and friction rust in the hub profile and replace if necessary. Do not clean clutch pressure plate and driven plate with a high pressure cleaner or component washing machine. 10. Inspect clutch pressure plate and driven plate (1) and replace if necessary. Inspect for: * Excessive wear * Burned friction surface * Oil on friction surface * Damaged spline hub * Damaged springs Note: The clutch driven plate has to be replaced if the lining projection is less than 0.5 mm (0.020 in) (arrows). 11. Inspect projection of lining at the clutch lining rivets. 12. Slide clutch driven plate onto the transmission input shaft and check for easy movement. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Page 3655 Installation Procedure 1. Clean 6 threads in flywheel for fastening clutch pressure plate. Note: Lettering transmission side faces the transmission. Center clutch driven plate using DT-6263-30 - centering drift (3) in conjunction with clutch center guide. 2. Install driven plate (1) and clutch pressure plate (2). 3. Preload clutch springs using DT-6263 - remover / installer. * Move DT-6263 - remover / installer (1) that it rests against the spring tangs of clutch pressure plate. * Turn DT-6263 - remover / installer clockwise to the stop. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Page 3656 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install 6 NEW clutch pressure plate bolts (1) and tighten crosswise to 28 Nm (21 lb ft). 5. Remove DT-6263 - remover / installer (1) from engine block. * Turn DT-6263 - remover / installer (3) counterclockwise to the stop. * Remove DT-6263-30 - centering drift (2) in conjunction with clutch center guide (arrow). * Remove 4 bolts of DT-6263 - remover / installer from engine block. 6. Install transmission. Refer to Transmission Replacement (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder Reservoir Hose Replacement (Left Hand Drive) Clutch Master Cylinder: Service and Repair Clutch Master Cylinder Reservoir Hose Replacement (Left Hand Drive) Clutch Master Cylinder Reservoir Hose Replacement (Left Hand Drive) Removal Procedure Note: Do NOT disconnect engine coolant hoses. 1. Remove the radiator surge tank clip (2). 2. Remove the radiator surge tank (1). 3. Position the radiator surge tank (1) aside. Note: Before disconnecting the reservoir tank hose, remove the clutch/brake fluid from the reservoir tank. 4. Remove the clutch master cylinder reservoir hose (1) from the reservoir tank and the master cylinder. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder Reservoir Hose Replacement (Left Hand Drive) > Page 3662 1. Install the clutch master cylinder reservoir hose (1) to the reservoir tank and the master cylinder. 2. Fill the reservoir with clutch/brake fluid up to the MAX level. 3. Install the radiator surge tank (1). 4. Install the radiator surge tank clip (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder Reservoir Hose Replacement (Left Hand Drive) > Page 3663 Clutch Master Cylinder: Service and Repair Clutch Master Cylinder Replacement (Left Hand Drive) Clutch Master Cylinder Replacement (Left Hand Drive) Removal Procedure 1. Remove battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). 2. Remove radiator surge tank clip (2). 3. Remove radiator surge tank (1) and lay aside. 4. Place basin underneath. 5. Extract as much brake fluid out of brake fluid reservoir as possible. 6. Remove clutch master cylinder reservoir hose (1) from clutch master cylinder. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder Reservoir Hose Replacement (Left Hand Drive) > Page 3664 7. Clip clutch actuator cylinder front (1) pipe out of 2 retainers (arrows). 8. Open retaining clip (arrow). 9. Disconnect clutch actuator cylinder front pipe (1) from clutch master cylinder. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder Reservoir Hose Replacement (Left Hand Drive) > Page 3665 Note: Press 2 latches (arrows) together. 10. Disconnect push rod retainer (1) from clutch pedal. 11. Remove 2 clutch master cylinder nuts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder Reservoir Hose Replacement (Left Hand Drive) > Page 3666 12. Remove clutch master cylinder (1). Installation Procedure 1. Install clutch master cylinder (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder Reservoir Hose Replacement (Left Hand Drive) > Page 3667 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install 2 clutch master cylinder nuts (1) and tighten to 18 Nm (13 lb ft). Note: The retaining clip (arrows) has to engage audibly. 3. Connect push rod retainer (1) to clutch pedal. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder Reservoir Hose Replacement (Left Hand Drive) > Page 3668 4. Connect clutch actuator cylinder front pipe (1) to clutch master cylinder. 5. Close retaining clip (arrow). 6. Clip clutch actuator cylinder front pipe (1) into 2 retainers (arrows). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder Reservoir Hose Replacement (Left Hand Drive) > Page 3669 7. Install clutch master cylinder reservoir hose (1) to clutch master cylinder. 8. Install radiator surge tank (1). 9. Install radiator surge tank clip (2). 10. Bleed hydraulic clutch system. Refer to Hydraulic Clutch System Bleeding (See: Service and Repair). 11. Install battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair Clutch Slave Cylinder: Service and Repair Clutch Actuator Cylinder Replacement (M32-6) Removal Procedure 1. Remove transmission. Refer to Transmission Replacement (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement ). 2. Remove clutch actuator cylinder pipe elbow (2) and clutch actuator cylinder pipe sleeve (1). 3. Remove 3 clutch actuator cylinder bolts (2). 4. Remove clutch actuator cylinder (1). Note: Discard clutch actuator cylinder seal. 5. Remove clutch actuator cylinder seal (3). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Page 3673 Installation Procedure 1. Clean 3 clutch actuator cylinder threads in clutch housing. 2. Install NEW clutch actuator cylinder seal (3). 3. Install clutch actuator cylinder (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install 3 NEW clutch actuator cylinder bolts (2) and tighten to 6 Nm (53 lb in). 5. Install clutch actuator cylinder pipe sleeve (1) and clutch actuator cylinder pipe elbow (2). 6. Install transmission. Refer to Transmission Replacement (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair Hydraulic Hose: Service and Repair Clutch Actuator Cylinder Front Pipe Replacement (LHD with MZ0,MZ4,MR5,MF3) Removal Procedure 1. Remove battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). 2. Remove radiator surge tank clip (2). 3. Remove radiator surge tank (1) and lay aside. 4. Place basin underneath. 5. Clip clutch actuator cylinder front pipe (2) out of 2 retainers. 6. Open retaining clip (1). 7. Disconnect clutch actuator cylinder front pipe from clutch actuator cylinder pipe elbow. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair > Page 3677 8. Remove 2 brake pressure modulator valve bracket bolts (1). 9. Open retaining clip (arrow). 10. Disconnect clutch actuator cylinder front pipe (1) from clutch master cylinder. Note: For removal of clutch actuator cylinder front pipe lift brake pressure modulator valve bracket carefully. 11. Remove clutch actuator cylinder front pipe. Installation Procedure Note: For installation of clutch actuator cylinder front pipe lift brake pressure modulator valve bracket carefully. 1. Install clutch actuator cylinder front pipe. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair > Page 3678 2. Connect clutch actuator cylinder front pipe (1) to clutch master cylinder. 3. Close retaining clip (arrow). 4. Connect clutch actuator cylinder front pipe (2) to clutch actuator cylinder pipe elbow. 5. Close retaining clip (1). 6. Clip clutch actuator cylinder front pipe into 2 retainers. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair > Page 3679 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install 2 brake pressure modulator valve bracket bolts (1) and tighten to 20 Nm (15 lb ft). 8. Install radiator surge tank (1). 9. Install radiator surge tank clip (2). 10. Bleed hydraulic clutch system. Refer to Hydraulic Clutch System Bleeding (See: Service and Repair). 11. Install battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations Clutch Pedal Position Sensor / Switch: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations > Page 3683 Clutch Pedal Position Sensor / Switch: Diagrams Component Connector End Views B25B Clutch Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations > Page 3684 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Position Sensor Replacement Removal Procedure 1. Disconnect the clutch pedal position sensor wiring harness plug. 2. Remove the clutch pedal position sensor bolt (2). 3. Remove the clutch pedal position sensor (1). Installation Procedure 1. Install the clutch pedal position sensor (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the clutch pedal position sensor bolt (2) and tighten to 3 Nm(27 lb in). 3. Connect the clutch pedal position sensor wiring harness plug. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations > Page 3685 4. Learn clutch pedal position sensor, refer to Clutch Pedal Position Sensor Learn (See: Manual Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > Vehicle - Engine Crankcase and Subsystems Flushing Info. Continuously Variable Transmission/Transaxle: Technical Service Bulletins Vehicle - Engine Crankcase and Subsystems Flushing Info. INFORMATION Bulletin No.: 04-06-01-029E Date: April 29, 2010 Subject: Unnecessary Flushing Services, Additive Recommendations and Proper Utilization of GM Simplified Maintenance Schedule to Enhance Customer Service Experience Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and add information about the proper transmission flush procedure. Please discard Corporate Bulletin Number 04-06-01-029D (Section 06 - Engine/Propulsion System). An Overview of Proper Vehicle Service General Motors is aware that some companies are marketing tools and equipment to support a subsystem flushing procedures. These dedicated machines are in addition to many engine oil, cooling system, fuel system, A/C, transmission flush and steering system additives available to the consumer. GM Vehicles under normal usage do not require any additional procedures or additives beyond what is advised under the former Vehicle Maintenance Schedules or the current Simplified Maintenance Schedules. Do not confuse machines available from Kent-Moore/SPX that are designed to aid and accelerate the process of fluid changing with these flushing machines. Engine Crankcase Flushing General Motors Corporation does not endorse or recommend engine crankcase flushing for any of its gasoline engines. Analysis of some of the aftermarket materials used for crankcase flushing indicate incompatibility with GM engine components and the potential for damage to some engine seals and bearings. Damage to engine components resulting from crankcase flushing IS NOT COVERED under the terms of the New Vehicle Warranty. GM Authorized Service Information: Detailed, Descriptive, and Complete If a specific model vehicle or powertrain need is identified, GM will issue an Authorized Service Document containing a procedure and, if required, provide, make available, or require the specific use of a machine, tool or chemical to accomplish proper vehicle servicing. An example of this is fuel injector cleaning. Due to variation in fuel quality in different areas of the country, GM has recognized the need for fuel injector cleaning methods on some engines, though under normal circumstances, this service is not part of the maintenance requirements. GM has published several gasoline fuel injector cleaning bulletins that fully outline the methods to be used in conjunction with GM Part Numbered solutions to accomplish proper and safe cleaning of the fuel injectors with preventative maintenance suggestions to maintain optimum performance. You may refer to Corporate Bulletin Numbers 03-06-04-030 and 04-06-04-051 for additional information on this subject. Subsystem Flushing Flushing of A/C lines, radiators, transmission coolers, and power steering systems are recognized practices to be performed after catastrophic failures or extreme corrosion when encountered in radiators. For acceptable A/C flushing concerns, refer to Corporate Bulletin Number 01-01-38-006. This practice is NOT required or recommended for normal service operations. The use of external transmission fluid exchange or flush machines is NOT recommended for the automatic or manual transmission. Use of external machines to replace the fluid may affect the operation or durability of the transmission. Transmission fluid should only be replaced by draining and refilling following directions in SI. Refer to Automatic/Manual Transmission Fluid and Filter Replacement. Approved Transmission Flushing Tool (Transmission Cooler Only) The Automatic Transmission Oil Cooler Flush and Flow Test Tool is recommended for GM vehicles. Refer to Transmission Fluid Cooler Flushing and Flow Test in SI using the J 45096. Service Is Important to You and Your Customer General Motors takes great pride in offering our dealerships and customers high quality vehicles that require extremely low maintenance over the life of the vehicle. This low cost of ownership builds repeat sales and offers our customers measurable economy of operation against competing vehicles. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > Vehicle - Engine Crankcase and Subsystems Flushing Info. > Page 3690 Providing responsible services at the proper intervals will greatly aid your dealership with repeat business, and additional services when required. Most customers appreciate and gain trust in the dealership that informs and offers them just what they need for continued trouble-free operation. Examine your service department's practices and verify that all Service Consultants and Technicians focus on customer satisfaction, vehicle inspections, and other products at time of service. Use this opportunity to upgrade the services you provide to your customers. Here are a few suggestions: - Take the time required to align your dealership service practices with the new GM Simplified Maintenance Schedule. Use the new vehicle Owner's Manual Maintenance I and II schedules to create a "mirror image" in your advertising and dealer service pricing that is easily understandable to your customer. Taking advantage of this new service strategy may greatly increase your dealership service sales and customer retention while decreasing the frequency of visits and inconvenience to your customer. - Review your program to ensure that all vehicles coming in are evaluated for safety and wear items. Examine all vehicles for tire condition, signs of misalignment, brake wear, exterior lamp functionality, exhaust condition, A/C cooling performance, SRS or Air Bag MIL, along with Service Engine Soon or Check Engine indicators. If the Service Engine Soon or Check Engine MIL is illuminated, it is vital that you inform the customer of the concerns with ignoring the indicator and what the required repair would cost. In addition to the possibility of increased emissions and driveability concerns, many customers are unaware that lower gas mileage may also result, with additional cost to the customer. - Be complete in your service recommendations. Some sales opportunities are not being fully pursued nationally. Focus on overlooked but required maintenance that has real benefits to the customer. Many vehicles are equipped with cabin air filters. If these filters are used beyond replacement time, they may impede airflow decreasing A/C and heating performance. Make sure these filters are part of your recommended service. Note that some of our vehicles may not have been factory equipped but will accept the filters as an accessory. - Express the value in maintaining the finish quality of the customer's vehicle at the Maintenance I and II visits. More fully utilize the vehicle prep personnel you already have in place. In today's world, many people simply ignore the finish of their vehicle, at best infrequently using an automatic car wash for exterior cleaning. Offer vehicle detailing services in stages from just a wash and wax to a complete interior cleaning. When paired with the Simplified Maintenance visit, this will increase customer satisfaction. On return, the customer gets a visibly improved vehicle that will be a source of pride of ownership along with a vehicle that is now fully maintained. Also, reinforce the improved resale value of a completely maintained vehicle. - For customers who clean and maintain the appearance of their vehicles themselves encourage the use of GM Vehicle Care products. Many customers may have never used GM Car Wash/Wax Concentrate, GM Cleaner Wax or a longtime product, GM Glass Cleaner, which is a favorite of many customers who try it just once. If your dealership give samples of these products with new car purchases, customers may already be sold on the product but not willing to make a special trip to the dealership. Capitalize on sales at this time. Stock shelves right at the Service counter with these products and consider instituting compensation programs for Service Consultants who suggest these products. Many consumers faced with an intimidating wall full of car care products sold at local auto parts stores may find it comforting to purchase a fully tested product sold by GM that they know will not harm the finish of their vehicle. We suggest these competitively priced basic vehicle care products to emphasize: In USA: - #12378401 GM Vehicle Care Wash/Wax Concentrate 16 fl. oz. (0.473L) - #89021822 GM Vehicle Care Glass Cleaner Aerosol 18 oz. (510 g) - #12377966 GM Vehicle Care Cleaner Wax 16 fl. oz. (0.473L) - #1052929 GM Vehicle Care Chrome and Wire Wheel Cleaner 16 fl. oz. (0.473L) - #88861431 GM Vehicle Care Odor Eliminator 24 fl. oz. (0.710L) In Canada: - #10953203 GM Vehicle Care Wash & Wax Concentrate 473 mL - #992727 GM Glass Cleaner Aerosol 500 g - #10952905 GM Vehicle Care Liquid Cleaner/Wax 473 mL - #10953013 GM Vehicle Care Chrome Cleaner and Polish 454 mL - #10953202 GM Vehicle Care Wheel Brite 473 mL - #88901678 GM Vehicle Care Odor Eliminator 473 mL - Display signboards with the installed price for popular GM Accessories such as running boards and Tonneau Covers. Customers may not think to ask about these desirable items at the time of a service visit. - Finally, take advantage of the GM Goodwrench initiatives (Tire Program, Goodwrench Credit Card, etc. / Dealer Marketing Association (DMA) Promotions in Canada) to provide the customer with more reasons to identify your dealership as the best place to go for parts and service. Remember to utilize ALL of the service aspects you possess in your dealership to satisfy and provide value to your customer. Many businesses exist profitably as an oil change location, a vehicle repair facility, or a detailing shop alone. You already have the capabilities of all three and provide these services with the inherent trust of your customer, under the GM Mark of Excellence. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Testing and Inspection > Wheel Drive Shaft Outer Joint Inspection Constant Velocity Joint: Testing and Inspection Wheel Drive Shaft Outer Joint Inspection Wheel Drive Shaft Outer Joint Inspection Disassembly Procedure 1. Remove the outer constant velocity (CV) joint and boot from the wheel drive shaft. Refer to Front Wheel Drive Shaft Outer Joint and Boot Replacement (See: Service and Repair/Front Wheel Drive Shaft Outer Joint and Boot Replacement). 2. Remove any lubricant from the CV joint. Note: Position the cage and the inner race so they are level. 3. Install the outer CV joint assembly in a soft jawed vise. Note: The following procedure will have to be repeated until all the ball bearing are removed form the cage. 4. Using a brass drift (1), gentle tap the cage until the ball bearing can be removed from the cage. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Testing and Inspection > Wheel Drive Shaft Outer Joint Inspection > Page 3697 5. Using a small screwdriver, remove the ball bearings (1) from the CV joint (2). 6. Remove the ball bearings from the CV joint in sequence. Note: Position the cage so that the larger radius corners of the cage windows are facing up. 7. Position the cage (1) at a 90 degrees to the centerline of the outer race (2). 8. Align the cage windows with the lands of the outer race (2). 9. Lift and remove the cage (1) and the inner race from the outer race (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Testing and Inspection > Wheel Drive Shaft Outer Joint Inspection > Page 3698 10. Position the cage (2) and the inner race (1) so that the larger radius corners of the cage windows are up. 11. Rotate the inner race (1) 90 degrees to the center line of the cage (2). 12. Align the lands of the inner race (1) with the windows of the cage (2). 13. Move the inner race (1) land into the cage window (2). 14. Rotate the inner race (1) down and remove it from the cage (2). 15. Clean the following items thoroughly with the proper cleaning solvent: * The inner race * The outer race * The cage * The ball bearings * The exposed end of the wheel drive shaft Note: The internal parts of the CV joint are NOT SERVICED separately. The outer CV joint is serviced as an assembly. 16. If any of the above items are found to have excessive wear or are damaged, replace the outer CV joint as an assembly. Assembly Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Testing and Inspection > Wheel Drive Shaft Outer Joint Inspection > Page 3699 1. Position the cage (2) so that the larger radius corners of the cage windows are up. 2. Position the inner race (1) 90 degrees to the centerline of the cage (2). 3. Insert the inner race (1) through the bottom of the cage (2). 4. Align the lands of the inner race (1) with the windows of the cage (2). 5. Move the inner race (1) land into the cage window (2). 6. Rotate the inner race (1) down and remove it from the cage (2). 7. Rotate the inner race (1) within the cage (2) so that the grooved surface of the inner race (1) is facing up. 8. Align the inner race (1) ball bearing tracks with the cage (2) windows. 9. Wrap a clean shop towel around the CV joint outer race splined shaft. 10. Place the outer race (2) vertically in a bench vise. 11. Position the cage (1) and the inner race at a 90 degrees to the centerline of the outer race (2). 12. With the inner race and the cage (1) assembly in a vertical position, insert the cage and the inner race into the outer race (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Testing and Inspection > Wheel Drive Shaft Outer Joint Inspection > Page 3700 Note: The larger radius corners of the cage windows should be positioned up and the grooved surface of the inner race should be visible. 13. Position the cage (2) and the inner race so that they are level in the vise. 14. Rotate the appropriate component(s), and align the cage windows and the inner race ball bearing (1) tracks with the outer race ball bearing tracks. 15. Position a cage window and the inner race ball bearing track for the ball bearing installation. Note: When performing the following procedure, the opposing cage (2) window and the inner ball bearing (1) track will be accessible for the ball bearing installation. 16. Press down on the cage following one of the outer race ball bearing (1) tracks. 17. Install the ball bearing through the cage window onto the inner race ball bearing (1) track. Note: The following service procedure will have to be performed after each ball bearing (1) has been installed. 18. After the first ball bearing (1) has been installed, use a brass drift and a hammer and gently tap the cage in order to drive the cage and the inner race down completely in the outer race. Note: After the ball bearing (1) has been installed, there should be NO GAP between the ball bearing and the inner race. 19. Position the cage and the inner race so that they are level. 20. Using a plastic hammer, lightly tap the ball bearing (1) into place. 21. Install the ball bearings in sequence. 22. Repeat steps 18 thru 20 until all the ball bearings are installed. 23. Install the outer CV joint and boot on the wheel drive shaft. Refer to Front Wheel Drive Shaft Outer Joint and Boot Replacement (See: Service and Repair/Front Wheel Drive Shaft Outer Joint and Boot Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Testing and Inspection > Wheel Drive Shaft Outer Joint Inspection > Page 3701 Constant Velocity Joint: Testing and Inspection Wheel Drive Shaft Inner Joint Inspection Wheel Drive Shaft Inner Joint Inspection Inspection Procedure 1. Remove the wheel drive boot clamp (2) from the tripod housing (3). 2. Remove the wheel drive shaft tripod housing (3) from the wheel drive shaft. 3. Remove the wheel drive shaft tripod joint boot bushing (1). 4. Using a suitable cleaner, remove the excess grease from the tripod assembly. 5. Inspect the following items for damage or excessive wear: * The wheel drive shaft tripod boot * The wheel drive shaft tripod assembly * The wheel drive shaft tripod joint housing * The wheel drive shaft tripod joint bushing * The wheel drive shaft 6. If any of the internal parts are found to be excessively worn or damaged, replace the wheel drive shaft inner joint and boot. Refer to Front Wheel Drive Shaft Inner Joint and Boot Replacement (See: Service and Repair/Front Wheel Drive Shaft Inner Joint and Boot Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement Constant Velocity Joint: Service and Repair Front Wheel Drive Shaft Inner Joint and Boot Replacement Front Wheel Drive Shaft Inner Joint and Boot Replacement Special Tools * GE-396 - Snap Ring Pliers * CH-804 - Tensioner For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Remove the left or right wheel drive shaft, refer to Front Wheel Drive Shaft Replacement - Left Side (See: Service and Repair/Front Wheel Drive Shaft Replacement - Left Side) or Front Wheel Drive Shaft Replacement - Right Side (See: Service and Repair/Front Wheel Drive Shaft Replacement - Right Side) Caution: Do not cut through the wheel drive shaft inboard or outboard boot during service. Cutting through the boot may damage the sealing surface of the housing and the tripot or the constant velocity joint bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint. 2. If equipped with a small swage ring, use a hand grinder to cut through the swage ring, taking care not to damage the halfshaft bar, in order to remove the swage ring. Otherwise, remove the small seal retaining clamp with a side cutter. Discard the retaining clamp. 3. Remove the large seal retaining clamp (2) from the tripot joint with side cutters. Discard the large seal retaining clamp. 4. Separate the inboard seal from the trilobal tripot bushing (3) at the large diameter. 5. Slide the seal away from the joint along the halfshaft bar. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement > Page 3704 6. Remove the housing (1) from the tripot joint spider and the halfshaft bar (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement > Page 3705 7. Remove the spacer ring (1), spider assembly (2), spacer ring (3) (if equipped) using GE-396 pliers , and tripot boot (4). DISCARD the boot and rings. 8. Clean the halfshaft bar (5). Use a wire brush in order to remove any rust in the boot mounting area (grooves). 9. Inspect the needle rollers, needle bearings, and trunnion. Check the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate kit. Installation Procedure Note: Place a towel in the vise before inserting the halfshaft. 1. Mount the halfshaft into a vise. 2. Place the new small eared clamp (2) onto the small end of the joint seal (1). Slide the joint seal (1) and the eared clamp (2) onto the halfshaft bar. 3. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement > Page 3706 4. Crimp the eared clamp (1) using the CH-804 - tensioner (1), and a torque wrench. Tighten the eared clamp to 25 Nm (19 lb ft). 5. Install the spacer ring (2) into the groove of the halfshaft bar using Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement > Page 3707 6. Slide the tripot joint spider assembly (4) as far as it will go on the halfshaft bar. 7. Install the spacer ring (2) into the groove of the halfshaft bar, using GE-396 - pliers. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement > Page 3708 8. Place approximately half of the grease from the service kit in the halfshaft inboard seal. Use the remainder of the grease to repack the housing. Note: Ensure the trilobal tripot bushing (3) is flush with the face of the housing (1). 9. Install the trilobal tripot bushing (3) to housing (1). 10. Position the larger new seal retaining clamp (2) on the halfshaft inboard seal. 11. Slide the housing (1) over the tripot joint spider assembly on the halfshaft bar. 12. Slide the large diameter of the halfshaft inboard seal (2), with larger clamp (3) in place, over the outside of the trilobal tripot bushing and locate the lip of the seal in the groove. 13. Position the joint assembly at the proper vehicle dimension, a = 106 mm (4.00 in). 14. Carefully insert a thin flat blunt tool, no sharp edges, between the large seal opening and the trilobal tripot bushing in order to equalize the pressure. Remove the tool. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement > Page 3709 15. Crimp the eared clamp (1) using the CH-804 - tensioner (1), and a torque wrench. Tighten the eared clamp to 25 Nm (19 lb ft). 16. Fully stroke the joint several times to disperse the grease. 17. Install the left or right wheel drive shaft, refer to Front Wheel Drive Shaft Replacement - Left Side (See: Service and Repair/Front Wheel Drive Shaft Replacement - Left Side) or Front Wheel Drive Shaft Replacement - Right Side (See: Service and Repair/Front Wheel Drive Shaft Replacement - Right Side). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement > Page 3710 Constant Velocity Joint: Service and Repair Front Wheel Drive Shaft Outer Joint and Boot Replacement Front Wheel Drive Shaft Outer Joint and Boot Replacement Special Tools * GE-396 - Snap Ring Pliers * CH-804 - Tensioner For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Remove the left or right wheel drive shaft, refer to Front Wheel Drive Shaft Replacement - Left Side (See: Service and Repair/Front Wheel Drive Shaft Replacement - Left Side) or Front Wheel Drive Shaft Replacement - Right Side (See: Service and Repair/Front Wheel Drive Shaft Replacement - Right Side). 2. Clamp the drive axle shaft in a soft jawed vice. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement > Page 3711 Caution: Do not cut through the wheel drive shaft inboard or outboard boot during service. Cutting through the boot may damage the sealing surface of the housing and the tripot or the constant velocity joint bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint. 3. Use a flat-bladed tool, remove the boot clamp (2) from the constant velocity (CV) joint (1) and the boot (3). 4. Using a pair of side cutters, remove and discard the boot clamp (4) from the boot (3) and the wheel drive shaft (5). Replace with NEW clamps. 5. Using a block of wood and a hammer, remove the CV joint (2) from the wheel drive shaft (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement > Page 3712 6. Remove the boot (1) from the wheel drive shaft (2). 7. Inspect the outer CV joint for damage and wear. Refer to Wheel Drive Shaft Outer Joint Inspection (See: Testing and Inspection/Wheel Drive Shaft Outer Joint Inspection). Installation Procedure 1. Position the boot (1) on the wheel drive shaft (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement > Page 3713 2. Ensure that the boot (1) is properly seated in the groove (2) in the wheel drive shaft (3). 3. Place approximately half the lubricant (2) inside the CV joint boot (1) and the other half in the CV joint (3). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement > Page 3714 4. Using a block of wood and a hammer, install the CV joint on the wheel drive shaft (1). 5. Install the boot clamp (4) on the boot (3) and the wheel drive shaft (5). 6. Install the boot clamp (2) on the boot (3) and the CV joint housing (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Crimp the eared clamp using the CH-804 - tensioner (1), and a torque wrench. Tighten the eared clamp to 25 Nm (19 lb ft). 8. Remove the wheel drive shaft from the bench vise. 9. Move the CV joint in a circular motion 4 to 5 times to distribute the lubricant. 10. Install the left or right wheel drive shaft, refer to Front Wheel Drive Shaft Replacement - Left Side (See: Service and Repair/Front Wheel Drive Shaft Replacement - Left Side) or Front Wheel Drive Shaft Replacement - Right Side (See: Service and Repair/Front Wheel Drive Shaft Replacement - Right Side). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement Constant Velocity Joint Boot: Service and Repair Front Wheel Drive Shaft Inner Joint and Boot Replacement Front Wheel Drive Shaft Inner Joint and Boot Replacement Special Tools * GE-396 - Snap Ring Pliers * CH-804 - Tensioner For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Remove the left or right wheel drive shaft, refer to Front Wheel Drive Shaft Replacement - Left Side (See: Service and Repair/Front Wheel Drive Shaft Replacement - Left Side) or Front Wheel Drive Shaft Replacement - Right Side (See: Service and Repair/Front Wheel Drive Shaft Replacement - Right Side) Caution: Do not cut through the wheel drive shaft inboard or outboard boot during service. Cutting through the boot may damage the sealing surface of the housing and the tripot or the constant velocity joint bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint. 2. If equipped with a small swage ring, use a hand grinder to cut through the swage ring, taking care not to damage the halfshaft bar, in order to remove the swage ring. Otherwise, remove the small seal retaining clamp with a side cutter. Discard the retaining clamp. 3. Remove the large seal retaining clamp (2) from the tripot joint with side cutters. Discard the large seal retaining clamp. 4. Separate the inboard seal from the trilobal tripot bushing (3) at the large diameter. 5. Slide the seal away from the joint along the halfshaft bar. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement > Page 3719 6. Remove the housing (1) from the tripot joint spider and the halfshaft bar (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement > Page 3720 7. Remove the spacer ring (1), spider assembly (2), spacer ring (3) (if equipped) using GE-396 pliers , and tripot boot (4). DISCARD the boot and rings. 8. Clean the halfshaft bar (5). Use a wire brush in order to remove any rust in the boot mounting area (grooves). 9. Inspect the needle rollers, needle bearings, and trunnion. Check the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate kit. Installation Procedure Note: Place a towel in the vise before inserting the halfshaft. 1. Mount the halfshaft into a vise. 2. Place the new small eared clamp (2) onto the small end of the joint seal (1). Slide the joint seal (1) and the eared clamp (2) onto the halfshaft bar. 3. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement > Page 3721 4. Crimp the eared clamp (1) using the CH-804 - tensioner (1), and a torque wrench. Tighten the eared clamp to 25 Nm (19 lb ft). 5. Install the spacer ring (2) into the groove of the halfshaft bar using Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement > Page 3722 6. Slide the tripot joint spider assembly (4) as far as it will go on the halfshaft bar. 7. Install the spacer ring (2) into the groove of the halfshaft bar, using GE-396 - pliers. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement > Page 3723 8. Place approximately half of the grease from the service kit in the halfshaft inboard seal. Use the remainder of the grease to repack the housing. Note: Ensure the trilobal tripot bushing (3) is flush with the face of the housing (1). 9. Install the trilobal tripot bushing (3) to housing (1). 10. Position the larger new seal retaining clamp (2) on the halfshaft inboard seal. 11. Slide the housing (1) over the tripot joint spider assembly on the halfshaft bar. 12. Slide the large diameter of the halfshaft inboard seal (2), with larger clamp (3) in place, over the outside of the trilobal tripot bushing and locate the lip of the seal in the groove. 13. Position the joint assembly at the proper vehicle dimension, a = 106 mm (4.00 in). 14. Carefully insert a thin flat blunt tool, no sharp edges, between the large seal opening and the trilobal tripot bushing in order to equalize the pressure. Remove the tool. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement > Page 3724 15. Crimp the eared clamp (1) using the CH-804 - tensioner (1), and a torque wrench. Tighten the eared clamp to 25 Nm (19 lb ft). 16. Fully stroke the joint several times to disperse the grease. 17. Install the left or right wheel drive shaft, refer to Front Wheel Drive Shaft Replacement - Left Side (See: Service and Repair/Front Wheel Drive Shaft Replacement - Left Side) or Front Wheel Drive Shaft Replacement - Right Side (See: Service and Repair/Front Wheel Drive Shaft Replacement - Right Side). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement > Page 3725 Constant Velocity Joint Boot: Service and Repair Front Wheel Drive Shaft Outer Joint and Boot Replacement Front Wheel Drive Shaft Outer Joint and Boot Replacement Special Tools * GE-396 - Snap Ring Pliers * CH-804 - Tensioner For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Remove the left or right wheel drive shaft, refer to Front Wheel Drive Shaft Replacement - Left Side (See: Service and Repair/Front Wheel Drive Shaft Replacement - Left Side) or Front Wheel Drive Shaft Replacement - Right Side (See: Service and Repair/Front Wheel Drive Shaft Replacement - Right Side). 2. Clamp the drive axle shaft in a soft jawed vice. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement > Page 3726 Caution: Do not cut through the wheel drive shaft inboard or outboard boot during service. Cutting through the boot may damage the sealing surface of the housing and the tripot or the constant velocity joint bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint. 3. Use a flat-bladed tool, remove the boot clamp (2) from the constant velocity (CV) joint (1) and the boot (3). 4. Using a pair of side cutters, remove and discard the boot clamp (4) from the boot (3) and the wheel drive shaft (5). Replace with NEW clamps. 5. Using a block of wood and a hammer, remove the CV joint (2) from the wheel drive shaft (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement > Page 3727 6. Remove the boot (1) from the wheel drive shaft (2). 7. Inspect the outer CV joint for damage and wear. Refer to Wheel Drive Shaft Outer Joint Inspection (See: Constant Velocity Joint/Testing and Inspection/Wheel Drive Shaft Outer Joint Inspection). Installation Procedure 1. Position the boot (1) on the wheel drive shaft (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement > Page 3728 2. Ensure that the boot (1) is properly seated in the groove (2) in the wheel drive shaft (3). 3. Place approximately half the lubricant (2) inside the CV joint boot (1) and the other half in the CV joint (3). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot Replacement > Page 3729 4. Using a block of wood and a hammer, install the CV joint on the wheel drive shaft (1). 5. Install the boot clamp (4) on the boot (3) and the wheel drive shaft (5). 6. Install the boot clamp (2) on the boot (3) and the CV joint housing (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Crimp the eared clamp using the CH-804 - tensioner (1), and a torque wrench. Tighten the eared clamp to 25 Nm (19 lb ft). 8. Remove the wheel drive shaft from the bench vise. 9. Move the CV joint in a circular motion 4 to 5 times to distribute the lubricant. 10. Install the left or right wheel drive shaft, refer to Front Wheel Drive Shaft Replacement - Left Side (See: Service and Repair/Front Wheel Drive Shaft Replacement - Left Side) or Front Wheel Drive Shaft Replacement - Right Side (See: Service and Repair/Front Wheel Drive Shaft Replacement - Right Side). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Page 3733 Wheel Bearing: Service and Repair Front Wheel Bearing and Hub Replacement Special Tools EN-45059 - Torque Angle Sensor Kit For equivalent regional tools, refer to Special Tools (See: Steering and Suspension/Suspension/Tools and Equipment/Front Suspension). Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the brake rotor. Refer to Front Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Front Brake Rotor Replacement). 3. Remove the wheel speed sensor screw (2). 4. Remove the wheel speed sensor (1) from the steering knuckle. 5. Remove the wheel drive shaft from the front wheel bearing/hub. Refer to Front Wheel Drive Shaft Replacement - Left Side (See: Axle Shaft Assembly/Service and Repair/Front Wheel Drive Shaft Replacement - Left Side) and/or Front Wheel Drive Shaft Replacement - Right Side (See: Axle Shaft Assembly/Service and Repair/Front Wheel Drive Shaft Replacement - Right Side). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Page 3734 6. Remove and DISCARD the front wheel bearing/hub bolts (1). 7. Remove the front wheel bearing/hub (1) and front brake shield (2) from the steering knuckle. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Page 3735 1. Position the front brake shield (2) and front wheel bearing/hub (1) assembly in the steering knuckle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the NEW front wheel bearing/hub bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Page 3736 3. Tighten the bearing/hub bolts (1) in 3 passes. Use the EN-45059 - angle meter. * First pass to 90 Nm (66 lb ft) * Second pass to 60° * Third pass to 15° 4. Install the wheel drive shaft at the front wheel bearing/hub. Refer to Front Wheel Drive Shaft Replacement - Left Side (See: Axle Shaft Assembly/Service and Repair/Front Wheel Drive Shaft Replacement - Left Side) or Front Wheel Drive Shaft Replacement - Right Side (See: Axle Shaft Assembly/Service and Repair/Front Wheel Drive Shaft Replacement - Right Side). 5. Install the wheel speed sensor (1) to the steering knuckle. 6. Install the wheel speed sensor screw (2) and tighten to 6 Nm (53 lb in). 7. Install the brake rotor. Refer to Front Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Front Brake Rotor Replacement). 8. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Wheel Drive Shaft Nut First Pass......................................................................................................... ............................................................................................150 Nm (111 lb ft) Release....................... .............................................................................................................................................................. ............................................45° Third Pass............................................................................................................................................ .......................................................250 Nm (184 lb ft) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Tighten the 6 automatic transmission flex plate bolts in a cross sequence to.................................................................................................. ...........................................................35 Nm (26 lb ft) flex plate bolts in a cross sequence to an addi tional..................................................................................................................................................... .......30° flex plate bolts in a cross sequence to an additional............................................................................ ................................................................................15° Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 3744 Flex Plate: Service and Repair Automatic Transmission Flex Plate Replacement Special Tools * EN-470-B - Angular Torque Wrench * EN-652 - Flywheel Holder For equivalent regional tools, refer to Special Tools (See: Engine, Cooling and Exhaust/Engine/Tools and Equipment). Removal Procedure 1. Open hood. 2. Remove the automatic transmission. Refer to Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission Replacement). 3. Install EN-652 - flywheel holder (1) in order to fix the automatic transmission flex plate (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 3745 4. Remove the 6 automatic transmission flex plate bolts (2). 5. Remove the automatic transmission flex plate (1). Installation Procedure 1. Clean the 6 screw bores. Rework if necessary. 2. Install the automatic transmission flex plate (1). 3. Install the 6 automatic transmission flex plate bolts (2). 4. Install EN-652 - flywheel holder (1) in order to fix the automatic transmission flex plate (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the 6 automatic transmission flex plate bolts in a cross sequence to 35 Nm(26 lb ft). 6. Tighten the 6 automatic transmission flex plate bolts in a cross sequence to an additional 30°.Use EN-470-B - wrench. 7. Tighten the 6 automatic transmission flex plate bolts in a cross sequence to an additional 15°.Use EN-470-B - wrench. 8. Install automatic transmission. Refer to Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 3746 9. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications 6 engine flywheel bolts (2) Tighten the 6 engine flywheel bolts in a cross sequence to................................................................. ..............................................................................................60 Nm (44 lb ft) flywheel bolts in a cross sequence to an additional..................................................................................................................... ........................................45° flywheel bolts in a cross sequence to an additional.............................................................................. ...............................................................................15° Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 3750 Flywheel: Service and Repair Engine Flywheel Replacement (1.4L LUH and LUJ) Special Tools * EN-470-B - Angular Torque Wrench * EN-652 - Flywheel Holder For equivalent regional tools, refer to Special Tools (See: Engine, Cooling and Exhaust/Engine/Tools and Equipment). Removal Procedure 1. Open hood. 2. Remove clutch pressure and driven plate from engine flywheel. Refer to Clutch Pressure and Driven Plate Replacement (LUJ, LUW with MF3, MZ0, or MZ4) (See: Clutch/Clutch Disc/Service and Repair). 3. Install EN-652 - flywheel holder (1) in order to fix the engine flywheel (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 3751 4. Remove the 6 engine flywheel bolts (2). 5. Remove the engine flywheel (1). Installation Procedure 1. Clean the 6 screw bores. Rework if necessary. 2. Install the engine flywheel (1). 3. Install the 6 engine flywheel bolts (2). 4. Install EN-652 - flywheel holder (1) in order to fix the engine flywheel (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the 6 engine flywheel bolts in a cross sequence to 60 Nm (44 lb ft). 6. Tighten the 6 engine flywheel bolts in a cross sequence to an additional 45°. Use EN-470-B - wrench. 7. Tighten the 6 engine flywheel bolts in a cross sequence to an additional 15°. Use EN-470-B - wrench. 8. Install clutch pressure and driven plate. Refer to Clutch Pressure and Driven Plate Replacement (LUJ, LUW with MF3, MZ0, or MZ4) (See: Clutch/Clutch Disc/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 3752 9. Install transmission. Refer to Clutch Pressure and Driven Plate Replacement (LUJ, LUW with MF3, MZ0, or MZ4) (See: Clutch/Clutch Disc/Service and Repair). 10. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair Automatic or Manual Transmission Control Lever Trim Cover Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Recalls for Fluid - M/T: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory Fluid - M/T: Recalls Campaign - Transmission Fluid Overfill From Factory SERVICE UPDATE Bulletin No.: 11008A Date: February 01, 2011 Subject: 11008A - Service Update for Inventory and Customer Vehicles - Transmission Fluid Overfill - Drain Excess Fluid - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Manual Transmission (MF3/MZ0) Supercede: The illustration for Step 9 in the Service Procedure has been revised to eliminate confusion on the amount of fluid to remove. Technicians are to remove 0.4L of transmission fluid after allowing the fluid to drain completely from the plug hole. Please discard all copies of bulletin 11008, issued January 2011. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to drain excess transmission fluid on certain 2011 model year Chevrolet Cruze vehicles with manual transmissions (MF3/MZ0). These vehicles may have received more than the required amount of transmission fluid, which could result in a hard shift and reduced fuel economy. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. Parts Information PN 55563377, plug, has been temporarily excluded from RIM. A sufficient number of plugs are being pre-shipped to involved dealers beginning January 21, 2011. The pre-shipped parts can be identified with control "Cruze-Recall", and will be shipped from Lansing, MI via Overnight Delivery. After you have received your preshipment of plugs, if you should still need additional parts, you can order them from General Motors Customer Care and Aftersales (GMCC&A;). Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Recalls for Fluid - M/T: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory > Page 3767 2. Remove the front compartment insulator. Refer to Front Compartment Insulator Replacement in SI. Oil Level Plug Shown on Manual Transmission Out of Vehicles Note There are three oil plugs on the manual transmission. There is a fill plug that is located on the top of the transmission below the battery tray. There is also a drain plug on the bottom of the transmission on the driver's side of the vehicle. The oil level plug (1) is located above the drain plug on the driver's side of the vehicle. Refer to the illustration. 3. Locate the oil level plug. 4. Place a basin below the transmission. 5. Place a shop towel or piece of plastic over the frame/front suspension as shown in the illustration. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Recalls for Fluid - M/T: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory > Page 3768 6. Remove the oil level plug. 7. Discard the oil level plug. 8. Allow the fluid to drain completely from the plug hole. Caution To preserve fluid quality and avoid harsh transmission shifts, after allowing the fluid to drain completely from the plug hole, remove 0.4L of transmission fluid. 9. Using a syringe and a 7.1mm (9/32 in) rubber hose, remove 0.4L of transmission fluid. 10. Clean all dirt and debris from the transmission oil level plug area. 11. Install a new oil level plug. Tighten Tighten the plug to 17 Nm (12.5 lb ft). 12. Remove the shop towel or plastic from the frame/front suspension. 13. Remove the transmission fluid from the vehicle frame, transmission, suspension and engine. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Recalls for Fluid - M/T: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory > Page 3769 14. Install the front compartment insulator. Refer to Front Compartment Insulator Replacement in SI. 15. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - M/T: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory Fluid - M/T: All Technical Service Bulletins Campaign - Transmission Fluid Overfill From Factory SERVICE UPDATE Bulletin No.: 11008A Date: February 01, 2011 Subject: 11008A - Service Update for Inventory and Customer Vehicles - Transmission Fluid Overfill - Drain Excess Fluid - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Manual Transmission (MF3/MZ0) Supercede: The illustration for Step 9 in the Service Procedure has been revised to eliminate confusion on the amount of fluid to remove. Technicians are to remove 0.4L of transmission fluid after allowing the fluid to drain completely from the plug hole. Please discard all copies of bulletin 11008, issued January 2011. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to drain excess transmission fluid on certain 2011 model year Chevrolet Cruze vehicles with manual transmissions (MF3/MZ0). These vehicles may have received more than the required amount of transmission fluid, which could result in a hard shift and reduced fuel economy. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. Parts Information PN 55563377, plug, has been temporarily excluded from RIM. A sufficient number of plugs are being pre-shipped to involved dealers beginning January 21, 2011. The pre-shipped parts can be identified with control "Cruze-Recall", and will be shipped from Lansing, MI via Overnight Delivery. After you have received your preshipment of plugs, if you should still need additional parts, you can order them from General Motors Customer Care and Aftersales (GMCC&A;). Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - M/T: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory > Page 3775 2. Remove the front compartment insulator. Refer to Front Compartment Insulator Replacement in SI. Oil Level Plug Shown on Manual Transmission Out of Vehicles Note There are three oil plugs on the manual transmission. There is a fill plug that is located on the top of the transmission below the battery tray. There is also a drain plug on the bottom of the transmission on the driver's side of the vehicle. The oil level plug (1) is located above the drain plug on the driver's side of the vehicle. Refer to the illustration. 3. Locate the oil level plug. 4. Place a basin below the transmission. 5. Place a shop towel or piece of plastic over the frame/front suspension as shown in the illustration. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - M/T: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory > Page 3776 6. Remove the oil level plug. 7. Discard the oil level plug. 8. Allow the fluid to drain completely from the plug hole. Caution To preserve fluid quality and avoid harsh transmission shifts, after allowing the fluid to drain completely from the plug hole, remove 0.4L of transmission fluid. 9. Using a syringe and a 7.1mm (9/32 in) rubber hose, remove 0.4L of transmission fluid. 10. Clean all dirt and debris from the transmission oil level plug area. 11. Install a new oil level plug. Tighten Tighten the plug to 17 Nm (12.5 lb ft). 12. Remove the shop towel or plastic from the frame/front suspension. 13. Remove the transmission fluid from the vehicle frame, transmission, suspension and engine. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - M/T: > 11008A > Feb > 11 > Campaign - Transmission Fluid Overfill From Factory > Page 3777 14. Install the front compartment insulator. Refer to Front Compartment Insulator Replacement in SI. 15. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Front Wheel Drive Shaft Seal Replacement - Left Side Seals and Gaskets: Service and Repair Front Wheel Drive Shaft Seal Replacement - Left Side Front Wheel Drive Shaft Seal Replacement - Left Side Special Tools * CH-466-A - Gear, Bearing Remover / Installer * DT-519 - Installer Drift * DT-523 - Remover / Installer For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Remove left front wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement - Left Side (See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Front Wheel Drive Shaft Replacement - Left Side). 2. Remove 4 front differential carrier flange bolts (3) and 4 washers (2). Remove front differential carrier flange (1) from transmission. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Front Wheel Drive Shaft Seal Replacement - Left Side > Page 3782 3. Remove front wheel drive shaft oil seal (1) from front differential carrier flange (2). Put front differential carrier flange on CH-466-A - remover/installer (5) and press front wheel drive shaft oil seal out of front differential carrier flange using DT-523-1 - remover / installer (3) in conjunction with DT-523-3 - remover / installer (4). 4. Remove front differential carrier flange seal (2) from front differential carrier flange (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Front Wheel Drive Shaft Seal Replacement - Left Side > Page 3783 Note: Coat front differential carrier flange seal with NEW transmission fluid. 1. Install NEW front differential carrier flange seal (2) to front differential carrier flange (1). Note: Coat front wheel drive shaft oil seal with NEW transmission fluid. Press front wheel drive shaft oil seal into front differential carrier flange using DT-519 - installer drift (3). 2. Install NEW front wheel drive shaft oil seal (1) to front differential carrier flange (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Front Wheel Drive Shaft Seal Replacement - Left Side > Page 3784 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install front differential carrier flange (1) to transmission. Install 4 washers (2) and 4 NEW front differential carrier flange bolts (3) and tighten to 20 Nm +45° (15 lb ft +45°). 4. Install left front wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement - Left Side (See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Front Wheel Drive Shaft Replacement - Left Side). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Front Wheel Drive Shaft Seal Replacement - Left Side > Page 3785 Seals and Gaskets: Service and Repair Front Wheel Drive Shaft Seal Replacement - Right Side Front Wheel Drive Shaft Seal Replacement - Right Side (1.4L LUJ) Special Tools * DT-519 - Installer Drift * DT-586 - Remover Hook * DT-7004 - Slide Hammer For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Remove front wheel drive intermediate shaft. Refer to Front Wheel Drive Intermediate Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Front Wheel Drive Intermediate Shaft Replacement). 2. Remove front wheel drive shaft oil seal (1) using DT-7004 - slide hammer (3) in conjunction with DT-586 - hook (2). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Front Wheel Drive Shaft Seal Replacement - Left Side > Page 3786 Note: Coat seal lips with NEW transmission fluid. 1. Install NEW front wheel drive shaft oil seal (1) using DT-519 - installer drift (2) with hammer. 2. Install front wheel drive intermediate shaft. Refer to Front Wheel Drive Intermediate Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Front Wheel Drive Intermediate Shaft Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations Clutch Pedal Position Sensor / Switch: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations > Page 3791 Clutch Pedal Position Sensor / Switch: Diagrams Component Connector End Views B25B Clutch Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations > Page 3792 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Position Sensor Replacement Removal Procedure 1. Disconnect the clutch pedal position sensor wiring harness plug. 2. Remove the clutch pedal position sensor bolt (2). 3. Remove the clutch pedal position sensor (1). Installation Procedure 1. Install the clutch pedal position sensor (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the clutch pedal position sensor bolt (2) and tighten to 3 Nm(27 lb in). 3. Connect the clutch pedal position sensor wiring harness plug. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations > Page 3793 4. Learn clutch pedal position sensor, refer to Clutch Pedal Position Sensor Learn (See: Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Manual Transmission Shift Lever and Selector Lever Cable Adjustment Shifter M/T: Service and Repair Manual Transmission Shift Lever and Selector Lever Cable Adjustment Manual Transmission Shift Lever and Selector Lever Cable Adjustment Special Tools DT-527-A - Adjuster For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Remove the transmission control lever trim cover. Refer to Automatic or Manual Transmission Control Lever Trim Cover Replacement (See: Automatic Transmission/Transaxle/Lamps and Indicators - A/T/Shift Indicator/Service and Repair). 2. Remove the front floor console storage tray. Refer to Front Floor Console Storage Tray Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Storage Tray Replacement). 3. Remove the shift lever and selector lever cable adjust locks (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Manual Transmission Shift Lever and Selector Lever Cable Adjustment > Page 3798 4. Lock the transmission control with DT-527-A - adjuster (1). 5. Lock transmission control housing (2) DT-527-A - adjuster (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Manual Transmission Shift Lever and Selector Lever Cable Adjustment > Page 3799 1. Install the shift lever and selector lever cable adjust locks (1). 2. Remove the DT-527-A - adjuster from the transmission control. 3. Install the front floor console storage tray. Refer to Front Floor Console Storage Tray Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Storage Tray Replacement). 4. Install the transmission control lever trim cover. Refer to Automatic or Manual Transmission Control Lever Trim Cover Replacement (See: Automatic Transmission/Transaxle/Lamps and Indicators - A/T/Shift Indicator/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Manual Transmission Shift Lever and Selector Lever Cable Adjustment > Page 3800 Shifter M/T: Service and Repair Manual Transmission Shift Lever and Selector Lever Cable Replacement Manual Transmission Shift Lever and Selector Lever Cable Replacement Removal Procedure 1. Remove transmission control. Refer to Transmission Control Replacement (See: Transmission Control Replacement). 2. Remove battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). 3. Using a suitable pry tool, carefully remove shift lever and selector lever cable (2) from transmission control housing (3). 4. Remove shift lever and selector lever cable from shift lever and selector lever cable bracket (1). 5. Remove shift lever and selector lever cable (1) from bulkhead. 6. Remove shift lever and selector lever cable from inside the vehicle. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Manual Transmission Shift Lever and Selector Lever Cable Adjustment > Page 3801 1. Install shift lever and selector lever cable from inside the vehicle. 2. Install shift lever and selector lever cable (1) to bulkhead. 3. Install shift lever and selector lever cable (2) to shift lever and selector lever cable bracket (1). 4. Install shift lever and selector lever cable to transmission control housing (3). 5. Install transmission control. Refer to Transmission Control Replacement (See: Transmission Control Replacement). 6. Install battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Manual Transmission Shift Lever and Selector Lever Cable Adjustment > Page 3802 Shifter M/T: Service and Repair Selector and Shift Lever Cable Bracket Replacement Selector and Shift Lever Cable Bracket Replacement Removal Procedure 1. Remove battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). 2. Using a suitable pry tool, carefully remove shift lever and selector lever cable (2) from transmission control housing (3) using. 3. Remove shift lever and selector lever cable from shift lever and selector lever cable bracket (1). 4. Remove 2 shift lever and selector lever cable bracket bolts (1). 5. Remove shift lever and selector lever cable bracket (2). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Manual Transmission Shift Lever and Selector Lever Cable Adjustment > Page 3803 1. Install shift lever and selector lever cable bracket (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install 2 shift lever and selector lever cable bracket bolts (1) and tighten to 20 Nm (15 lb ft). 3. Install shift lever and selector lever cable (2) to shift lever and selector lever cable bracket (1). 4. Install shift lever and selector lever cable to transmission control housing (3). 5. Install battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Manual Transmission Shift Lever and Selector Lever Cable Adjustment > Page 3804 Shifter M/T: Service and Repair Transmission Control Replacement Transmission Control Replacement Removal Procedure 1. Remove front floor console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). 2. Unlock shift lever and selector lever cable adjust locks (2). 3. Clip shift lever and selector lever cable (3) out of transmission control lever housing (1). 4. Remove 4 transmission control lever bolts (1). 5. Remove transmission control lever (2). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Manual Transmission Shift Lever and Selector Lever Cable Adjustment > Page 3805 1. Install NEW transmission control lever (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install 4 transmission control lever bolts (1) and tighten to 8 Nm (71 lb in). 3. Slide shift lever and selector lever cable into shift lever and selector lever cable adjust locks (2). Note: Do not lock yet. 4. Clip shift lever and selector lever cable (3) into transmission control lever housing (1). 5. Adjust shift lever and selector lever cable. Refer to Manual Transmission Shift Lever and Selector Lever Cable Adjustment (See: Manual Transmission Shift Lever and Selector Lever Cable Adjustment). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Front Mount Replacement Transmission Mount: Service and Repair Transmission Front Mount Replacement Transmission Front Mount Replacement Removal Procedure 1. Raise vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove transmission front mount bolt (1). 3. Remove 2 transmission front mount bolts (1). 4. Remove transmission front mount (2). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Front Mount Replacement > Page 3810 1. Install transmission front mount (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install 2 transmission front mount bolts (1) and tighten to 100 Nm (74 lb ft). 3. Install transmission front mount bolt (1) and tighten to 100 Nm (74 lb ft). 4. Lower vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Front Mount Replacement > Page 3811 Transmission Mount: Service and Repair Transmission Mount Bracket Replacement - Left Side Transmission Mount Bracket Replacement - Left Side Removal Procedure 1. Remove battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). 2. Raise vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Install the engine support fixture. For the 1.4L engine, refer to Engine Support Fixture (See: Engine, Cooling and Exhaust/Engine/Service and Repair/Overhaul/1. Engine Support Fixture). For the 1.8L engine, refer to Engine Support Fixture (See: Engine, Cooling and Exhaust/Engine/Service and Repair/Overhaul/1. Engine Support Fixture). 4. Lower vehicle. 5. Remove 3 transmission mount bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Front Mount Replacement > Page 3812 6. Remove 2 transmission mount bolts (1, 3) and transmission mount nut (2). 7. Remove transmission mount (1). 8. Remove 3 transmission mount bracket bolts (1). 9. Remove transmission mount bracket (2). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Front Mount Replacement > Page 3813 1. Install transmission mount bracket (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install 3 transmission mount bracket bolts (1) and tighten to 100 Nm (74 lb ft). 3. Install transmission mount (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Front Mount Replacement > Page 3814 4. Install 2 transmission mount bolts (1, 3) and tighten to 62 Nm (46 lb ft). 5. Install transmission mount nut (2) and tighten to 62 Nm (46 lb ft). 6. Install 3 transmission mount bolts (1) and tighten to 50 Nm + 60° - 75° (37 lb ft + 60° - 75°). 7. Raise vehicle. 8. Remove the engine support fixture. 9. Lower vehicle. 10. Install battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Front Mount Replacement > Page 3815 Transmission Mount: Service and Repair Transmission Mount Bracket Replacement - Rear Transmission Mount Bracket Replacement - Rear Removal Procedure 1. Raise vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Support rear of powertrain using a suitable jack stand. 3. Remove transmission rear mount bolt (1). 4. Remove 3 transmission rear mount bolts (1). 5. Remove transmission rear mount (2). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Front Mount Replacement > Page 3816 1. Install transmission rear mount (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install 3 transmission rear mount bolts (1) and tighten to 100 Nm (74 lb ft). 3. Install transmission rear mount bolt (1) and tighten to 100 Nm (74 lb ft). 4. Remove jack stand. 5. Lower vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Front Mount Replacement > Page 3817 Transmission Mount: Service and Repair Transmission Mount Replacement - Left Side Transmission Mount Replacement - Left Side Removal Procedure 1. Remove battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). 2. Raise vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Install the engine support fixture. For the 1.4L engine, refer to Engine Support Fixture (See: Engine, Cooling and Exhaust/Engine/Service and Repair/Overhaul/1. Engine Support Fixture). For the 1.8L engine, refer to Engine Support Fixture (See: Engine, Cooling and Exhaust/Engine/Service and Repair/Overhaul/1. Engine Support Fixture). 4. Lower vehicle. 5. Remove 3 transmission mount bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Front Mount Replacement > Page 3818 6. Remove 2 transmission mount bolts (1, 3) and transmission mount nut (2). 7. Remove transmission mount (1). Installation Procedure 1. Install transmission mount (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Front Mount Replacement > Page 3819 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install 2 transmission mount bolts (1, 3) and tighten to 62 Nm (46 lb ft). 3. Install transmission mount nut (2) and tighten to 62 Nm (46 lb ft). 4. Install 3 transmission mount bolts (1) and tighten to 50 Nm (37 lb ft) + 60°-75°. 5. Raise vehicle. 6. Remove the engine support fixture. 7. Lower vehicle. 8. Install battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Front Mount Replacement > Page 3820 Transmission Mount: Service and Repair Transmission Rear Mount Replacement Transmission Rear Mount Replacement Removal Procedure 1. Remove steering gear. Refer to Steering Gear Replacement (See: Steering and Suspension/Steering/Steering Gear/Service and Repair/Steering Gear Replacement). 2. Remove transmission rear mount bracket. Refer to Transmission Mount Bracket Replacement Rear (See: Transmission Mount Bracket Replacement - Rear). 3. Remove 2 transmission rear mount nuts (3) and 2 transmission rear mount bolts (1). 4. Remove transmission rear mount (2). Installation Procedure 1. Install transmission rear mount (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Front Mount Replacement > Page 3821 2. Install 2 transmission rear mount bolts (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install 2 transmission rear mount nuts (3) and tighten to 110 Nm (82 lb ft). 4. Install transmission rear mount bracket. Refer to Transmission Mount Bracket Replacement - Rear (See: Transmission Mount Bracket Replacement - Rear). 5. Install steering gear. Refer to Steering Gear Replacement (See: Steering and Suspension/Steering/Steering Gear/Service and Repair/Steering Gear Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues Control Module: All Technical Service Bulletins Campaign - Thermostat Sticks Open Causes Shift Issues SERVICE UPDATE Bulletin No.: 10399A Date: December 02, 2010 Subject: 10399A - Service Update for Inventory and Customer Vehicles - Powertrain Improvements - Thermostat Sticks in Open Position and Shift Quality - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with a 1.4L Turbo Engine (LUJ) Supercede: The Subject and Purpose in this bulletin are being revised to advise that the new ECM calibration will also address shift quality issues.Please discard all copies of bulletin 10399, issued November 2010. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to reprogram the engine control module (ECM) on certain 2011 model year Chevrolet Cruze vehicles equipped with a 1.4L turbo engine (LUJ). These vehicles may have a condition where the thermostat sticks in the open position. If this occurs, diagnostic codes will be set and the Service Vehicle Soon light/message will illuminate. These vehicles may also have transmission shift quality issues due to calibration values. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. Additionally, a list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should also be checked for vehicle eligibility. Parts Information No parts are required for this update. Service Procedure Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 11/29/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming. 2. Reprogram the engine control module (ECM) and transmission control module (TCM) in sequence. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI or Tech 2(R) to the vehicle. If using MDI, connect to programming terminal with the cable (USB or LAN). 2. Select J-2534 MDI or J-2534 Tech 2(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues > Page 3832 3. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. 4. Follow the on-screen instructions. 3. Clear all DTCs using the GDS or Tech 2(R). Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Recalls for Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues Control Module: Recalls Campaign - Thermostat Sticks Open Causes Shift Issues SERVICE UPDATE Bulletin No.: 10399A Date: December 02, 2010 Subject: 10399A - Service Update for Inventory and Customer Vehicles - Powertrain Improvements - Thermostat Sticks in Open Position and Shift Quality - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with a 1.4L Turbo Engine (LUJ) Supercede: The Subject and Purpose in this bulletin are being revised to advise that the new ECM calibration will also address shift quality issues.Please discard all copies of bulletin 10399, issued November 2010. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to reprogram the engine control module (ECM) on certain 2011 model year Chevrolet Cruze vehicles equipped with a 1.4L turbo engine (LUJ). These vehicles may have a condition where the thermostat sticks in the open position. If this occurs, diagnostic codes will be set and the Service Vehicle Soon light/message will illuminate. These vehicles may also have transmission shift quality issues due to calibration values. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. Additionally, a list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should also be checked for vehicle eligibility. Parts Information No parts are required for this update. Service Procedure Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 11/29/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming. 2. Reprogram the engine control module (ECM) and transmission control module (TCM) in sequence. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI or Tech 2(R) to the vehicle. If using MDI, connect to programming terminal with the cable (USB or LAN). 2. Select J-2534 MDI or J-2534 Tech 2(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Recalls for Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues > Page 3838 3. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. 4. Follow the on-screen instructions. 3. Clear all DTCs using the GDS or Tech 2(R). Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3839 Control Module: Locations Powertrain Component Views Transmission Components (MH8) 1 - T12 Automatic Transmission Assembly 2 - X1 Transmission Control Module X1 3 - T12 Automatic Transmission Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair Transmission Position Switch/Sensor: Service and Repair Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Special Tools DT-41229 - Manual Shaft Pin Installer For equivalent regional tools, refer to Special Tools (See: Automatic Transmission/Transaxle/Tools and Equipment). Removal Procedure 1. Remove the control valve body. Refer to Control Valve Body Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 2. Remove the manual shaft detent lever hub pin (1) using a pry bar and pliers. 3. Remove and DISCARD the manual shift shaft pin (5). 4. Remove the manual shaft (2). 5. Disconnect the actuator rod (3) from the detent lever assembly. Do not remove the actuator rod from the transmission case. 6. Remove the manual shaft detent (with shift position switch) lever assembly (4). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Page 3845 1. Connect the actuator rod (3) to the detent lever assembly. 2. Install the manual shaft detent (with shift position switch) lever assembly (4). 3. Install the manual shaft (2). 4. Install the manual shaft detent lever hub pin (1) to height of 7.9 mm (0.38 in) (b). Caution: Use J 41229 to install the manual shaft pin at the correct height in order to properly secure the manual shaft. If you install the pin too deep, the case bore may crack. 5. Install the NEW manual shift shaft pin (5) using DT-41229 - pin installer. Use a NEW pin to ensure proper engagement with the case. 6. Inspect pin installed height is within 7.2-8.2 mm (0.28-0.32 in) (a). 7. Install the control valve body. Refer to Control Valve Body Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 8. Perform the transmission adaptive values learn procedure. Refer to Transmission Adaptive Values Learn (See: Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Transmission Speed Sensor: Locations Component Location 1 - Reaction Carrier Assembly 2 - Control Valve Body Assembly 3 - Input Carrier Assembly 4 Valve Channel Plate 5 - Output Carrier Assembly 6 - Park Gear 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Drive Link Assembly 9 - Drive Sprocket 10 - Torque Converter Assembly 11 - A/Trans Fluid Pump Assembly 12 - Differential Carrier Assembly 13 - Front Differential Ring Gear 14 - Driven Sprocket 15 - 1-2-3-4 Clutch Assembly 16 - Low and Reverse Clutch Assembly 17 - 2-6 Clutch Assembly 18 - 3-5 Reverse Clutch Assembly 19 - 4-5-6 Clutch Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 3849 20 - A/Trans Input Speed Sensor Assembly 21 - Reaction Sun Gear Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Replacement Transmission Speed Sensor: Service and Repair Output Speed Sensor Replacement Output Speed Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Replacement > Page 3852 Transmission Speed Sensor: Service and Repair Input Speed Sensor Replacement Input Speed Sensor Replacement Removal Procedure 1. Remove the control valve body. Refer to Control Valve Body Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 2. Remove the input speed sensor bolt (2) M6 x 23. 3. Unlock the 2 retaining tabs inside the transmission housing. 4. Remove the input speed sensor (3). 5. Remove the 3 input speed sensor seals (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Replacement > Page 3853 1. Install the 3 input speed sensor seals (1). 2. Install the input speed sensor (3). 3. Verify that the retaining tabs are locked completely. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the input speed sensor bolt (2) M6 x 23 and tighten to 9 Nm (80 lb in). 5. Install the control valve body. Refer to Control Valve Body Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 6. Perform the transmission adaptive values learn procedure. Refer to Transmission Adaptive Values Learn (See: Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations Clutch Pedal Position Sensor / Switch: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations > Page 3858 Clutch Pedal Position Sensor / Switch: Diagrams Component Connector End Views B25B Clutch Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations > Page 3859 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Position Sensor Replacement Removal Procedure 1. Disconnect the clutch pedal position sensor wiring harness plug. 2. Remove the clutch pedal position sensor bolt (2). 3. Remove the clutch pedal position sensor (1). Installation Procedure 1. Install the clutch pedal position sensor (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the clutch pedal position sensor bolt (2) and tighten to 3 Nm(27 lb in). 3. Connect the clutch pedal position sensor wiring harness plug. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations > Page 3860 4. Learn clutch pedal position sensor, refer to Clutch Pedal Position Sensor Learn (See: Manual Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Shift Interlock Solenoid: Diagrams Component Connector End Views S3 Automatic Transmission Shift Lever (MH8) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 3867 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure Note: The automatic transmission shift lock control actuator is part of the automatic transmission control and cannot be removed separately. Remove the shift lock control actuator. Refer to Transmission Control Replacement (See: Automatic Transmission/Transaxle/Shifter A/T/Service and Repair/Transmission Control Replacement). Installation Procedure Install the shift lock control actuator. Refer to Transmission Control Replacement (See: Automatic Transmission/Transaxle/Shifter A/T/Service and Repair/Transmission Control Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Shift Solenoid Valve State and Gear Ratio Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 3871 Shift Solenoid: Service and Repair Control Solenoid Valve and Transmission Control Module Assembly Replacement Removal Procedure 1. Remove the transmission control valve body cover. Refer to Control Valve Body Cover Replacement (LDE, LUW) (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement)Control Valve Body Cover Replacement (LLU, LUJ) (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement). 2. Disconnect the output speed sensor electrical connector (2). 3. Disconnect the shift position switch electrical connector (3). 4. Disconnect the input speed sensor electrical connector (1). 5. Remove the 3 control valve body bolts (1) M5 x 40.5. 6. Remove the 12 control valve body bolts (2) M6 x 97. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 3872 7. Remove the control solenoid valve assembly (3) with transmission control module. Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 8. Remove the control solenoid valve assembly filter plate (4). Discard the filter plate. It is not reusable. 9. Inspect the pressure switch seals for damage or contamination. Replace the control solenoid valve assembly as necessary. 10. Inspect the channel plate bolt pass through holes for damage or burnelling. Any damage could cause leaking. Replace as necessary. Installation Procedure Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 1. Install a NEW control solenoid valve assembly filter plate (4) to prevent fluid leaks past the fluid seals. 2. Install the control solenoid valve assembly (3) with transmission control module. 3. Hand start the control valve body bolts (1, 2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 3873 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Secure the 12 control valve body bolts (2) M6 x 97 and tighten in sequence to 12 Nm(106 lb in). 5. Secure the 3 control valve body bolts (1) M5 x 40.5 and tighten in sequence to 8 Nm(71 lb in). 6. Connect the input speed sensor electrical connector (1). 7. Connect the output speed sensor electrical connector (2). 8. Install the transmission control valve body cover. Refer to Control Valve Body Cover Replacement (LDE, LUW) (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement)Control Valve Body Cover Replacement (LLU, LUJ) (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Cover Replacement). 9. After repairs, refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for programming and set up procedures. 10. Perform the transmission adaptive values learn. Refer to Transmission Adaptive Values Learn (See: Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair Automatic or Manual Transmission Control Lever Trim Cover Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues Control Module: All Technical Service Bulletins Campaign - Thermostat Sticks Open Causes Shift Issues SERVICE UPDATE Bulletin No.: 10399A Date: December 02, 2010 Subject: 10399A - Service Update for Inventory and Customer Vehicles - Powertrain Improvements - Thermostat Sticks in Open Position and Shift Quality - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with a 1.4L Turbo Engine (LUJ) Supercede: The Subject and Purpose in this bulletin are being revised to advise that the new ECM calibration will also address shift quality issues.Please discard all copies of bulletin 10399, issued November 2010. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to reprogram the engine control module (ECM) on certain 2011 model year Chevrolet Cruze vehicles equipped with a 1.4L turbo engine (LUJ). These vehicles may have a condition where the thermostat sticks in the open position. If this occurs, diagnostic codes will be set and the Service Vehicle Soon light/message will illuminate. These vehicles may also have transmission shift quality issues due to calibration values. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. Additionally, a list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should also be checked for vehicle eligibility. Parts Information No parts are required for this update. Service Procedure Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 11/29/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming. 2. Reprogram the engine control module (ECM) and transmission control module (TCM) in sequence. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI or Tech 2(R) to the vehicle. If using MDI, connect to programming terminal with the cable (USB or LAN). 2. Select J-2534 MDI or J-2534 Tech 2(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues > Page 3889 3. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. 4. Follow the on-screen instructions. 3. Clear all DTCs using the GDS or Tech 2(R). Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Recalls for Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues Control Module: Recalls Campaign - Thermostat Sticks Open Causes Shift Issues SERVICE UPDATE Bulletin No.: 10399A Date: December 02, 2010 Subject: 10399A - Service Update for Inventory and Customer Vehicles - Powertrain Improvements - Thermostat Sticks in Open Position and Shift Quality - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with a 1.4L Turbo Engine (LUJ) Supercede: The Subject and Purpose in this bulletin are being revised to advise that the new ECM calibration will also address shift quality issues.Please discard all copies of bulletin 10399, issued November 2010. This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to reprogram the engine control module (ECM) on certain 2011 model year Chevrolet Cruze vehicles equipped with a 1.4L turbo engine (LUJ). These vehicles may have a condition where the thermostat sticks in the open position. If this occurs, diagnostic codes will be set and the Service Vehicle Soon light/message will illuminate. These vehicles may also have transmission shift quality issues due to calibration values. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. Additionally, a list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should also be checked for vehicle eligibility. Parts Information No parts are required for this update. Service Procedure Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Use TIS2WEB on or after 11/29/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming. 2. Reprogram the engine control module (ECM) and transmission control module (TCM) in sequence. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI or Tech 2(R) to the vehicle. If using MDI, connect to programming terminal with the cable (USB or LAN). 2. Select J-2534 MDI or J-2534 Tech 2(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Recalls for Control Module: > 10399A > Dec > 10 > Campaign - Thermostat Sticks Open Causes Shift Issues > Page 3895 3. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. 4. Follow the on-screen instructions. 3. Clear all DTCs using the GDS or Tech 2(R). Warranty Transaction Information Submit a transaction using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3896 Control Module: Locations Powertrain Component Views Transmission Components (MH8) 1 - T12 Automatic Transmission Assembly 2 - X1 Transmission Control Module X1 3 - T12 Automatic Transmission Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair Transmission Position Switch/Sensor: Service and Repair Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Special Tools DT-41229 - Manual Shaft Pin Installer For equivalent regional tools, refer to Special Tools (See: Automatic Transmission/Transaxle/Tools and Equipment). Removal Procedure 1. Remove the control valve body. Refer to Control Valve Body Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 2. Remove the manual shaft detent lever hub pin (1) using a pry bar and pliers. 3. Remove and DISCARD the manual shift shaft pin (5). 4. Remove the manual shaft (2). 5. Disconnect the actuator rod (3) from the detent lever assembly. Do not remove the actuator rod from the transmission case. 6. Remove the manual shaft detent (with shift position switch) lever assembly (4). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Page 3902 1. Connect the actuator rod (3) to the detent lever assembly. 2. Install the manual shaft detent (with shift position switch) lever assembly (4). 3. Install the manual shaft (2). 4. Install the manual shaft detent lever hub pin (1) to height of 7.9 mm (0.38 in) (b). Caution: Use J 41229 to install the manual shaft pin at the correct height in order to properly secure the manual shaft. If you install the pin too deep, the case bore may crack. 5. Install the NEW manual shift shaft pin (5) using DT-41229 - pin installer. Use a NEW pin to ensure proper engagement with the case. 6. Inspect pin installed height is within 7.2-8.2 mm (0.28-0.32 in) (a). 7. Install the control valve body. Refer to Control Valve Body Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 8. Perform the transmission adaptive values learn procedure. Refer to Transmission Adaptive Values Learn (See: Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Transmission Speed Sensor: Locations Component Location 1 - Reaction Carrier Assembly 2 - Control Valve Body Assembly 3 - Input Carrier Assembly 4 Valve Channel Plate 5 - Output Carrier Assembly 6 - Park Gear 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Drive Link Assembly 9 - Drive Sprocket 10 - Torque Converter Assembly 11 - A/Trans Fluid Pump Assembly 12 - Differential Carrier Assembly 13 - Front Differential Ring Gear 14 - Driven Sprocket 15 - 1-2-3-4 Clutch Assembly 16 - Low and Reverse Clutch Assembly 17 - 2-6 Clutch Assembly 18 - 3-5 Reverse Clutch Assembly 19 - 4-5-6 Clutch Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 3906 20 - A/Trans Input Speed Sensor Assembly 21 - Reaction Sun Gear Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Replacement Transmission Speed Sensor: Service and Repair Output Speed Sensor Replacement Output Speed Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Replacement > Page 3909 Transmission Speed Sensor: Service and Repair Input Speed Sensor Replacement Input Speed Sensor Replacement Removal Procedure 1. Remove the control valve body. Refer to Control Valve Body Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 2. Remove the input speed sensor bolt (2) M6 x 23. 3. Unlock the 2 retaining tabs inside the transmission housing. 4. Remove the input speed sensor (3). 5. Remove the 3 input speed sensor seals (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Replacement > Page 3910 1. Install the 3 input speed sensor seals (1). 2. Install the input speed sensor (3). 3. Verify that the retaining tabs are locked completely. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the input speed sensor bolt (2) M6 x 23 and tighten to 9 Nm (80 lb in). 5. Install the control valve body. Refer to Control Valve Body Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Control Valve Body Replacement). 6. Perform the transmission adaptive values learn procedure. Refer to Transmission Adaptive Values Learn (See: Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations Clutch Pedal Position Sensor / Switch: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations > Page 3915 Clutch Pedal Position Sensor / Switch: Diagrams Component Connector End Views B25B Clutch Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations > Page 3916 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Position Sensor Replacement Removal Procedure 1. Disconnect the clutch pedal position sensor wiring harness plug. 2. Remove the clutch pedal position sensor bolt (2). 3. Remove the clutch pedal position sensor (1). Installation Procedure 1. Install the clutch pedal position sensor (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the clutch pedal position sensor bolt (2) and tighten to 3 Nm(27 lb in). 3. Connect the clutch pedal position sensor wiring harness plug. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Locations > Page 3917 4. Learn clutch pedal position sensor, refer to Clutch Pedal Position Sensor Learn (See: Manual Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Acceleration/Deceleration Sensor > Component Information > Locations Acceleration/Deceleration Sensor: Locations Instrument Panel/Center Console Component Views Center Console Components 2 of 5 1 - G307 Tunnel 2 - B119 Multi-axis Acceleration Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Acceleration/Deceleration Sensor > Component Information > Locations > Page 3923 Acceleration/Deceleration Sensor: Diagrams Component Connector End Views B119 Multi-Axis Acceleration Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - K17 Electronic Brake Control Module (EBCM) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 3927 Electronic Brake Control Module: Diagrams Component Connector End Views K17 Electronic Brake Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 3928 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module Replacement (MK60 EC) Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement (MK60 EC) Electronic Brake Control Module Replacement (MK60 EC) Removal Procedure The electronic brake control module may not be replaced singly. Always replace control module in assemble with brake pressure modulator valve. Refer to Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake Pressure Modulator Valve Replacement). Installation Procedure The electronic brake control module may not be replaced singly. Always replace control module in assemble with brake pressure modulator valve. Refer to Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake Pressure Modulator Valve Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module Replacement (MK60 EC) > Page 3931 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement (MK60 P) Electronic Brake Control Module Replacement (MK60 P) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module Replacement (MK60 EC) > Page 3932 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Testing and Inspection Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection Brake Pressure Modulator Valve Pressure Sensor Calibration The brake pressure sensor does not require calibration often. Calibration of the brake pressure sensor might be required after certain service procedures are performed. Some of these procedures are as follows: * Electronic brake control module (EBCM) replacement * Brake pressure modulator valve assembly replacement The Brake Pressure Sensor Calibration procedure can be completed with a scan tool using the following steps: 1. Apply the parking brake, or set the transmission in the P position. 2. Release the brake pedal. 3. Install the scan tool to the data link connector. 4. Ignition ON, engine OFF 5. Select Brake Pressure Sensor Calibration in the EBCM Configuration/Reset Functions list. 6. Follow the scan tool directions to complete the calibration procedure. 7. Clear any DTCs that may be set. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve Replacement Brake Pressure Modulator Valve Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Prepare electronic brake control module for replacement. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). 2. Turn the ignition to the OFF position. Note: Do NOT disconnect engine coolant hoses. 3. Remove the radiator surge tank clip (2). 4. Remove the radiator surge tank (1). Position the radiator surge tank (1) aside. Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. 5. Disconnect the electrical connector from the EBCM/EBTCM. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement > Page 3938 Note: Cap the brake pipe fittings to prevent brake fluid loss and contamination. 6. Remove the 6 brake pipes (1, 2) from the BPMV. 7. Remove the 2 BPMV bracket bolts (2). 8. Remove the BPMV bracket assembly (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement > Page 3939 9. Remove the 3 BPMV bracket bolts. 10. Remove the BPMV (2). 11. Remove the BPMV insulator (1) from the BPMV bracket (3). Installation Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Install the BPMV insulator (1) to the BPMV bracket (3). 2. Install the BPMV (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 3 BPMV bracket bolts (4) and tighten to 10 Nm(89 lb in). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement > Page 3940 4. Install the BPMV bracket assembly (1). 5. Install the 2 BPMV bracket bolts (2) and tighten to 20 Nm(15 lb ft). 6. Install the 6 brake pipes (1, 2) to the BPMV and tighten to 18 Nm(14 lb ft). 7. Connect the electrical connector to the EBCM/EBTCM. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement > Page 3941 8. Install the radiator surge tank (1). 9. Install the radiator surge tank clip (2). 10. Program the EBCM. Refer to Electronic Brake Control Module Programming and Setup (See: Testing and Inspection/Programming and Relearning/Electronic Brake Control Module Programming and Setup). 11. Perform the diagnostic system check - Vehicle. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). 12. Calibrate the brake pressure modulator valve pressure sensor. Refer to Brake Pressure Modulator Valve Pressure Sensor Calibration (See: Testing and Inspection). Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 13. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Pressure)). 14. Center the steering angle sensor. Refer to Steering Angle Sensor Centering (See: Sensors and Switches/Sensors and Switches - Steering and Suspension/Sensors and Switches - Steering/Steering Angle Sensor/Service and Repair/Procedures). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement > Page 3942 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve Bracket Replacement Brake Pressure Modulator Valve Bracket Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Turn the ignition to the OFF position. Note: Do NOT disconnect engine coolant hoses. 2. Remove the radiator surge tank clip (2). 3. Remove the radiator surge tank (1). Position the radiator surge tank (1) aside. Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. 4. Disconnect the electrical connector from the EBCM/EBTCM. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement > Page 3943 Note: Cap the brake pipe fittings to prevent brake fluid loss and contamination. 5. Remove the 6 brake pipes (1, 2) from the BPMV. 6. Remove the 2 BPMV bracket bolts (2). 7. Remove the BPMV bracket assembly (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement > Page 3944 8. Remove the 3 BPMV bracket bolts. 9. Remove the BPMV (2). 10. Remove the BPMV insulator (1) from the BPMV bracket (3). Installation Procedure 1. Install the BPMV insulator (1) to the BPMV bracket (3). 2. Install the BPMV (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 3 BPMV bracket bolts (4). Tighten the BPMV bracket bolts 10 Nm (89 lb in). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement > Page 3945 4. Install the BPMV bracket assembly (1). 5. Install the 2 BPMV bracket bolts (2) and tighten to 20 Nm (15 lb ft). 6. Install the 6 brake pipes (1, 2) to the BPMV and tighten to 18 Nm (14 lb ft). 7. Connect the electrical connector to the EBCM/EBTCM. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement > Page 3946 8. Install the radiator surge tank (1). 9. Install the radiator surge tank clip (2). 10. Program the EBCM. Refer to Electronic Brake Control Module Programming and Setup (See: Testing and Inspection/Programming and Relearning/Electronic Brake Control Module Programming and Setup). 11. Perform the diagnostic system check - Vehicle. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). 12. Calibrate the brake pressure modulator valve pressure sensor. Refer to Brake Pressure Modulator Valve Pressure Sensor Calibration (See: Testing and Inspection). Caution: When adding fluid to the brake master cylinder reservoir, use only GM approved or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 13. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Pressure)). 14. Center the steering angle sensor. Refer to Steering Angle Sensor Centering (See: Sensors and Switches/Sensors and Switches - Steering and Suspension/Sensors and Switches - Steering/Steering Angle Sensor/Service and Repair/Procedures). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Passenger Compartment/Roof Component Views Wheel Speed Sensor: Locations Passenger Compartment/Roof Component Views Passenger Compartment/Roof Component Views Left Rear of the Passenger Compartment Components 1 of 2 1 - F105L Roof Rail Air Bag - Left 2 - B63LR Side Impact Sensor - Left Rear 3 - B5LR Wheel Speed Sensor - Left Rear 4 - G309 Panel Rear - Left 5 - G401 Panel Rear - Left Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Passenger Compartment/Roof Component Views > Page 3951 Wheel Speed Sensor: Locations Wheels/Vehicle Underbody Component Views Wheels/Vehicle Underbody Component Views Right Rear Frame and Underbody Components 1 - B5RR Wheel Speed Sensor - Right Rear Left Front Frame and Underbody Components 1 of 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Passenger Compartment/Roof Component Views > Page 3952 1 - B5LF Wheel Speed Sensor - Left Front Right Front Frame and Underbody Components Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Passenger Compartment/Roof Component Views > Page 3953 1 - B5RF Wheel Speed Sensor - Right Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 3954 Wheel Speed Sensor: Diagrams Component Connector End Views B5LF Wheel Speed Sensor - Left Front B5LR Wheel Speed Sensor - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 3955 B5RF Wheel Speed Sensor - Right Front B5RR Wheel Speed Sensor - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 3956 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement Front Wheel Speed Sensor Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the wheel speed sensor screw (2) from the steering knuckle. 4. Remove the wheel speed sensor (1). 5. Remove the wiring harness retainers from the frame. 6. Disconnect the electrical connector. 7. Remove wheel speed sensor (1) from the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 3959 Installation Procedure 1. Install the wheel speed sensor (1) to the vehicle. 2. Connect the electrical connector. 3. Install the wiring harness retainers to the frame. 4. Install the wheel speed sensor (1) to the steering knuckle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the wheel speed sensor screw (2) and tighten to 9 Nm (80 lb in). 6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 3960 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement (Disc Brake) Rear Wheel Speed Sensor Replacement (Disc Brake) Removal Procedure 1. Remove rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). 2. Remove the wheel speed sensor screw (2) from the steering knuckle. 3. Remove the wheel speed sensor (1). 4. Remove the wiring harness (3) from the bracket (4). 5. Remove the wiring harness (2) retainers (3) from the brake hose (4). 6. Remove the wiring harness (2) from the body retainer (1). 7. Replace the body retainer (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 3961 8. Disconnect the electrical connector (1). 9. Remove wheel speed sensor from the vehicle. Installation Procedure 1. Install the wheel speed sensor to the vehicle. 2. Connect the electrical connector (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 3962 3. Install the wiring harness (2) retainers (3) to the TOP SIDE of brake hose (4), using the marking points of old wiring harness. 4. Install the wiring harness (2) to the NEW body retainer (1). 5. Install the wheel speed sensor (1) to the steering knuckle. 6. Install the wiring harness (3) at the bracket (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the wheel speed sensor screw (2) and tighten to 6 Nm (53 lb in). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 3963 8. Check the correct installation position of the wiring harness (1). The wiring harness MUST be routed on top of the brake hose. If necessary adjust retainers (2) to the marking positions on the brake hose. 9. Apply tension to the wiring harness (1) between the retainers (2) for the correct routing. 10. Push down the brake hose by hand, to assure the correct installation position. 11. Install the rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 3964 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement (Drum Brake) Rear Wheel Speed Sensor Replacement (Drum Brake) Removal Procedure 1. Remove rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). 2. Remove the wheel speed sensor screw (2) from the steering knuckle. 3. Remove wheel speed sensor (1). 4. Remove wiring harness (3) from bracket (4). 5. Disconnect the electrical connector (1). 6. Remove wheel speed sensor from vehicle. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 3965 1. Install the wheel speed sensor to the vehicle. 2. Connect the electrical connector (1). 3. Install the wheel speed sensor (1) to steering knuckle. 4. Install wiring harness (3) at the bracket (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the wheel speed sensor screw (2) and tighten to 9 Nm (80 lb in). 6. Install rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Testing and Inspection Yaw Rate Sensor: Testing and Inspection Vehicle Yaw Sensor Learn The yaw sensor does not require calibration often. Calibration of the yaw rate sensor might be required after certain service procedures are performed. Some of these procedures are as follows: * Electronic brake control module (EBCM) replacement * Multi-axis acceleration sensor replacement The yaw rate sensor calibration procedure can be completed with a scan tool using the following steps: 1. Place vehicle on a level surface 2. Apply the parking brake, or set the transmission in the P position. 3. Install the scan tool to the data link connector. 4. Ignition ON, engine OFF. 5. Select Yaw Rate Sensor Reset in the Multi-axis Acceleration Sensor Module Configuration/Reset Functions list. 6. Follow the scan tool directions to complete the calibration procedure. 7. Select Yaw Rate Sensor Learn in the Multi-axis Acceleration Sensor Module Configuration/Reset Functions list. 8. Follow the scan tool directions to complete the calibration procedure. 9. Select Yaw Rate Sensor Learn in the EBCM Configuration/Reset Functions list. 10. Follow the scan tool directions to complete the calibration procedure. 11. Clear any DTCs that may be set. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Testing and Inspection > Page 3969 Yaw Rate Sensor: Service and Repair Vehicle Yaw Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Antilock Brake System Automated Bleed Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Note: Before performing the ABS Automated Bleed Procedure, first perform a pressure bleed of the base brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Hydraulic Brake System Bleeding (Pressure)). The automated bleed procedure is recommended when one of the following conditions exist: * Base brake system bleeding does not achieve the desired pedal height or feel * Extreme loss of brake fluid has occurred * Air ingestion is suspected in the secondary circuits of the brake modulator assembly The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run the pump in order to purge any air from the secondary circuits. These circuits are normally closed off, and are only opened during system initialization at vehicle start up and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped in these circuits to flow out toward the brake corners. Performing the Automated Bleed Procedure Caution: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove all four tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Inspect the brake system for leaks and visual damage. Repair or replace components as needed. 4. Lower the vehicle. 5. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test). 6. Install a scan tool. 7. Turn the ignition ON, with the engine OFF. 8. With the scan tool, establish communications with the ABS system. Select Special Functions. Select Automated Bleed from the Special Functions menu. 9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 10. Following the directions given on the scan tool, pressure bleed the base brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Hydraulic Brake System Bleeding (Pressure)). 11. Follow the scan tool directions until the desired brake pedal height is achieved. 12. If the bleed procedure is aborted, a malfunction exists. Perform the following steps before resuming the bleed procedure: * If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) , and diagnose the appropriate DTC. * If the brake pedal feels spongy, perform the conventional brake bleed procedure again. Refer to Hydraulic Brake System Bleeding (Manual) ( See: Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Hydraulic Brake System Bleeding (Pressure)). 13. When the desired pedal height is achieved, press the brake pedal to inspect for firmness. 14. Lower the vehicle. 15. Remove the scan tool. 16. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 17. Inspect the brake fluid level. Refer to Master Cylinder Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). 18. Road test the vehicle while inspecting that the pedal remains high and firm. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed > Page 3974 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add GM approved brake fluid from a clean, sealed brake fluid container. Refer to Maintenance. See: Maintenance If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Maintenance. See: Maintenance 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed > Page 3975 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed > Page 3976 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) Special Tools * CH-29532-A - Brake Pressure Bleeder, or equivalent * CH-35589-A - Brake Pressure Bleeder Adapter For equivalent regional tools, refer to Special Tools (See: Hydraulic System/Tools and Equipment). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Note: The transmission must be in the PARK position, the power button in the OFF position, and the brakes not applied to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 1. Place the transmission in PARK. 2. Place the power button in the OFF position. 3. Remove the remote keyless entry (RKE) transmitter and close all of the vehicle doors. 4. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 5. With the power button OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 6. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 6.2-6.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 6.2-6.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 7. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 8. Install the CH-35589-A - Brake Pressure Bleeder Adapter to the brake master cylinder reservoir. 9. Check the brake fluid level in the CH-29532-A - Brake Pressure Bleeder, or equivalent. Add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 10. Connect the CH-29532-A - Brake Pressure Bleeder, or equivalent , to the CH-35589-A - Brake Pressure Bleeder Adapter. 11. Charge the CH-29532-A - Brake Pressure Bleeder, or equivalent , air tank to 175-205 kPa (25-30 psi). 12. Open the CH-29532-A - Brake Pressure Bleeder, or equivalent , fluid tank valve to allow pressurized brake fluid to enter the brake system. 13. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 14. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve. 16. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 17. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed > Page 3977 tighten the bleeder valve. 18. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 19. Install a transparent hose over the end of the bleeder valve, then repeat steps 16-17. 20. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 21. Install a transparent hose over the end of the bleeder valve, then repeat steps 16-17. 22. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 23. Install a transparent hose over the end of the bleeder valve, then repeat steps 16-17. 24. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 25. Close the CH-29532-A - Brake Pressure Bleeder, or equivalent , fluid tank valve, then disconnect the CH-29532-A - Brake Pressure Bleeder, or equivalent , from the CH-35589-A - Brake Pressure Bleeder Adapter. 26. Remove the CH-35589-A - Brake Pressure Bleeder Adapter from the brake master cylinder reservoir. 27. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 28. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 29. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to Antilock Brake System Automated Bleed (See: Antilock Brake System Automated Bleed). 30. Turn the power button ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 31. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed > Page 3978 Brake Bleeding: Service and Repair Hydraulic Brake System Flushing Hydraulic Brake System Flushing Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination: * Fluid separation, indicating two types of fluid are present; a substance other than the recommended brake fluid has been introduced into the brake hydraulic system: - Swirled appearance-oil-based substance - Layered appearance-silicone-based substance * Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system: - Cloudy appearance-moisture - Dark appearance/suspended particles in fluid-dirt, rust, corrosion, brake dust 2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination. 3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: 1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (Left Hand Drive) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement) * Front Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement) * Rear Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement) * Front Brake Caliper Replacement (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement) * Rear Brake Caliper Replacement (with Dampener) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (with Dampener)) * Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake Pressure Modulator Valve Replacement) * Hydraulic Brake System Bleeding (Manual) (See: Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Hydraulic Brake System Bleeding (Pressure)) 2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (Left Hand Drive) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement); also perform the following: * Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement (See: Hydraulic System/Brake Fluid Reservoir/Service and Repair). * Replace the brake master cylinder reservoir cap diaphragm. * Front Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement) * Rear Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement) * Front Brake Caliper Overhaul (See: Disc Brake System/Brake Caliper/Service and Repair/Overhaul)or Front Brake Caliper Replacement (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement) * Rear Brake Caliper Replacement (with Dampener) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (with Dampener)) 4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The diaphragm may have allowed the moisture or Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed > Page 3979 particles to enter the hydraulic system. 5. Fill the brake master cylinder reservoir to the maximum-fill level with GM recommended brake fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications) for the recommended brake fluid. 6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) (See: Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Hydraulic Brake System Bleeding (Pressure)). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Recalls for Brake Pedal Assy: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Brake Pedal Assy: Recalls Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Recalls for Brake Pedal Assy: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 3988 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Recalls for Brake Pedal Assy: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 3989 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pedal Assy: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Brake Pedal Assy: All Technical Service Bulletins Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pedal Assy: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 3995 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pedal Assy: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 3996 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Page 3997 Brake Pedal Assy: Service and Repair Brake, Accelerator, and Clutch Pedal Replacement (Left Hand Drive) Removal Procedure 1. Remove the battery. Refer to Battery Replacement (See: Starting and Charging/Battery/Service and Repair/Removal and Replacement). 2. Remove the battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). Note: Do NOT disconnect engine coolant hoses. 3. Remove the radiator surge tank clip (2). 4. Remove the radiator surge tank (1). Position the radiator surge tank (1) aside. 5. Remove the BPMV bracket bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Page 3998 6. Remove the brake booster bolts (1). Note: * Do NOT open hydraulic brake system. * Second mechanic required. 7. Pull the brake booster and the BPMV assembly forward in order to get access to the brake pedal bracket nuts (1). 8. Remove the brake pedal bracket nuts (1). 9. Remove the instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Pad Cover Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Trim Pad Cover Replacement). 10. Remove the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Upper Trim Cover Replacement). 11. Remove the steering column lower trim cover. Refer to Steering Column Lower Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Lower Trim Cover Replacement). 12. Remove the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Intermediate Steering Shaft Replacement). 13. Remove the steering column. Refer to Steering Column Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Page 3999 14. Disconnect the brake pedal pushrod (1) from the brake pedal. 15. Replace click fit connector (1) between booster pushrod and brake pedal with new part. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Page 4000 16. Remove the clutch master cylinder nuts (2) from the pedal bracket, if equipped. 17. Disconnect clutch master cylinder push rod (1) from the clutch pedal, if equipped. 18. Remove the brake pedal bracket bolt (1) from the tie bar. 19. Separate wiring harness from pedal bracket. 20. Disconnect electrical connectors. 21. Remove brake and accelerator and clutch pedal assembly from vehicle. 22. Transfer component parts as needed. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Page 4001 1. Install the brake and accelerator and clutch pedal assembly to the vehicle. 2. Install wiring harness to brake pedal bracket. 3. Connect electrical connectors. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install brake pedal bracket bolts and tighten to 20 Nm (15 lb ft). 5. Connect clutch master cylinder push rod (1) to the clutch pedal, if equipped. 6. Install the clutch master cylinder nuts (2) to the pedal bracket, if equipped and tighten to 18 Nm (14 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Page 4002 7. Connect the brake pedal pushrod (1) to the brake pedal. 8. Install the steering column. Refer to Steering Column Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Replacement). 9. Install the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Intermediate Steering Shaft Replacement). 10. Install the steering column lower trim cover. Refer to Steering Column Lower Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Lower Trim Cover Replacement). 11. Install the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Upper Trim Cover Replacement). 12. Install the instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Pad Cover Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Trim Pad Cover Replacement). Note: * Do NOT open hydraulic brake system. * Second mechanic required. 13. Pull the brake booster and the BPMV assembly forward in order to get access to the brake pedal bracket nuts (1). 14. Install the pedal bracket nuts (1) and tighten to 20 Nm (15 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Page 4003 15. Install the brake booster bolts (1) and tighten to 19 Nm (15 lb ft). 16. Install the BPMV bracket bolts (1) and tighten to 20 Nm (15 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Page 4004 17. Install the BPMV bracket assembly (1). 18. Install the BPMV bracket bolts (2) and tighten to 20 Nm (15 lb ft). Note: Do NOT disconnect engine coolant hoses. 19. Install the radiator surge tank (1). 20. Install the radiator surge tank clip (2). 21. Install the battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray Replacement). 22. Install the battery. Refer to Battery Replacement (See: Starting and Charging/Battery/Service and Repair/Removal and Replacement). 23. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration (See: Accessories and Optional Equipment/Pedal Positioning System/Pedal Positioning Sensor/Service and Repair/Brake Pedal Position Sensor Calibration). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Testing and Inspection Brake Caliper: Testing and Inspection Brake Caliper Inspection 1. Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage. If any of these conditions are present, the brake caliper requires replacement. 2. Inspect the caliper piston dust boot seal (6) for cracks, tears, cuts, deterioration and/or improper seating in the caliper body. If any of these conditions are present, the brake caliper requires overhaul or replacement. 3. Renew brake caliper bleeder valve cap (3) if missing. 4. Check for blocked bleeder valve (2). 5. Inspect for smooth and complete travel of the caliper pistons into the caliper bores: The movement of the caliper pistons into the caliper bores should be smooth and even. If the caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement. Insert a discarded inner brake pad (2) or block of wood in front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the piston in the bore. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement Brake Caliper: Removal and Replacement Front Brake Caliper Bracket Replacement (15 inch Brake System) Front Brake Caliper Bracket Replacement (15 inch Brake System) Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 6. Remove the lower brake caliper guide pin bolt (4). Do NOT disconnect the hydraulic brake flexible hose (1) from the caliper (2). Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 7. Without disconnecting the hydraulic brake flexible hose (1), pivot the caliper (2) upward and separate from caliper bracket in direction of arrow. 8. Remove the brake pads (3). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4011 9. Remove the brake pad retainer springs (1). 10. If reusing the bracket, thoroughly clean the pad hardware mating surfaces of the caliper bracket, of any debris and corrosion. 11. Inspect the brake pad retainer springs (1) for the following: * Bent mounting tabs * Excessive corrosion * Looseness at the brake caliper mounting bracket * Looseness at the disc brake pads 12. If any of the conditions listed are found, the disc brake pad retainers require replacement. 13. Remove and DISCARD caliper bracket bolts (2). 14. Remove brake caliper bracket (1) from steering knuckle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4012 15. Inspect the caliper bracket (5). If the brake caliper bracket (5) is bent, cracked, or damaged, it requires replacement. 16. Inspect the brake caliper guide pins (3) for freedom of movement, and inspect the condition of the guide pin boots (4). Move the brake caliper guide pins (3) inboard and outboard within the brake caliper bracket (5), without disengaging the slides from the boots (4), and observe for the following: * Restricted caliper guide pin movement * Looseness in the brake caliper mounting bracket * Seized or binding caliper guide pins * Split or torn boots 17. If any of the conditions listed are found, the brake caliper guide pins (3) and/or boots (4) require replacement. Installation Procedure 1. Install the brake caliper bracket (1) to the steering knuckle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the NEW brake caliper bracket bolts (2) and tighten to 100 Nm (74 lb ft) + 60° - 75° Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4013 3. Apply a very thin coating of high temperature silicone brake lubricant to the pad hardware mating surfaces of the caliper bracket only. 4. Install the brake pad retainer springs (1). Note: The wear sensor equipped disc brake pad must be mounted inboard of the rotor with the leading edge of the sensor facing the brake rotor during forward wheel rotation, or at the top of the pad when installed in vehicle position. 5. Install the brake pads (3) to the brake caliper bracket. 6. Remove the support and reposition the brake caliper (2) over the brake pads and to the caliper bracket. Assure that guide pin bolts boots apply firmly. 7. Install guide pin bolts and tighten to 28 Nm (21 lb ft). 8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads. 13. Fill the master cylinder auxiliary reservoir to the proper level. Refer to Master Cylinder Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4014 Front Brake Caliper Replacement Front Brake Caliper Replacement Removal Procedure Warning Use of eye goggles is necessary to prevent personal injury. Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 6. Remove the brake hose-to-caliper bolt (3) from the brake caliper. 7. Remove the brake hose (2) from the brake caliper. Remove and discard the copper brake hose washers. These washers may be stuck to the brake caliper and/or the brake hose end. 8. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination. 9. Remove the brake caliper guide pin bolts (1). 10. Remove the brake caliper from the caliper bracket. 11. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: * Restricted caliper guide pin movement * Looseness in the brake caliper mounting bracket * Seized or binding caliper guide pins * Split or torn boots 12. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4015 1. Install the brake caliper to the brake caliper bracket. Note: Do not reuse the brake hose washers. 2. Install NEW copper brake hose washers (1) to the brake hose-to-caliper bolt and to the brake hose. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 3. Install the brake caliper guide pin bolts (1) and tighten to 28 Nm (21 lb ft). 4. Remove the caps or plugs from the brake caliper opening and the brake hose. 5. Install the brake hose (2) to the caliper. 6. Install brake hose-to-caliper bolt (3) to the caliper and tighten to 40 Nm (30 lb ft). 7. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Pressure)). 8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4016 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 10 and 11 until a firm brake pedal is obtained. This will properly seat the brake caliper piston and brake pads. Front Brake Caliper Hardware Replacement Front Brake Caliper Hardware Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 6. Remove the brake caliper lower guide pin bolt (2). Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 7. Without disconnecting the hydraulic brake flexible hose, pivot the caliper (1) upward and secure the caliper with heavy mechanics wire, or equivalent. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4017 8. Remove the brake pads (1) from the caliper mounting bracket 9. Remove the brake pad retainer springs (1) from the caliper bracket. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4018 10. Remove the brake caliper guide pins (3) from the brake caliper mounting bracket (1). 11. Remove the brake caliper pin boots (2) from the brake caliper mounting bracket (1). Installation Procedure 1. Apply a thin coat of high temperature silicone lube to the brake caliper guide pin boots. 2. Install the brake caliper pin boots (2) into the brake caliper mounting bracket (1). Do not hammer the caliper pin boots into the bracket. Ensure that the caliper pin boots are fully seated in the bracket. 3. Apply a thin coat of high temperature silicone lube to the brake caliper guide pins. 4. Install the brake caliper guide pins (3) to the brake caliper mounting bracket (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4019 5. Ensure the brake pad hardware mating surfaces are clean. 6. Install the brake pad retainers (1) to the brake caliper bracket. Note: The wear sensor equipped disc brake pad must be mounted inboard of the rotor with the leading edge of the sensor facing the brake rotor during forward wheel rotation, or at the top of the pad when installed in vehicle position. 7. Install the brake pads (1) to the caliper bracket. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4020 8. Remove the support, and rotate the brake caliper (1) into position over the disc brake pads and to the caliper mounting bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the lower brake caliper guide pin bolts (2) and tighten to 28 Nm (21 lb ft). 10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 11. Lower the vehicle. 12. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance. 13. Slowly release the brake pedal. 14. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads. 15. Fill the master cylinder auxiliary reservoir to the proper level. Refer to Master Cylinder Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). Rear Brake Caliper Hardware Replacement Rear Brake Caliper Hardware Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4021 6. Remove the upper brake caliper pin bolt (1). 7. Remove the brake caliper vibration dampener (3). 8. Remove the brake pads (1) from the caliper mounting bracket (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4022 9. Remove the brake pad retainer springs (1) from the caliper bracket (2). 10. Remove the brake caliper guide pins (3) from the brake caliper mounting bracket (1). 11. Remove the brake caliper pin boots (2) from the brake caliper mounting bracket (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4023 1. Apply a thin coat of high temperature silicone lube to the brake caliper guide pin boots. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications) for the recommended lubricant. 2. Install the brake caliper pin boots (2) into the brake caliper mounting bracket (1). Do not hammer the caliper pin boots into the bracket. Ensure that the caliper pin boots are fully seated in the bracket. 3. Apply a thin coat of high temperature silicone lube to the brake caliper guide pins. 4. Install the brake caliper guide pins (3) to the brake caliper mounting bracket (1). 5. Ensure the brake pad hardware mating surfaces are clean. 6. Install the brake pad retainers (1) to the brake caliper bracket and apply a thin coat of high temperature silicone lube to the brake pad retainers. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4024 Note: The wear sensor equipped disc brake pad must be mounted inboard of the rotor with the leading edge of the sensor facing the brake rotor during forward wheel rotation, or at the top of the pad when installed in vehicle position. 7. Install the brake pads (1) to the caliper bracket. 8. Install the brake caliper (2) to the brake caliper bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the lower brake caliper pin bolt (1) and tighten to 28 Nm (20 lb ft). 10. Install the brake caliper vibration dampener (3) and tighten to 28 Nm (20 lb ft). Note: Position of brake caliper piston cavity MUST aligned horizontally to the embossed marking of brake caliper in order to prevent an appropriate installation. 11. Check position of piston cavity after assembling caliper. 12. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 13. Lower the vehicle. 14. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4025 15. Slowly release the brake pedal. 16. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads. 17. Fill the master cylinder auxiliary reservoir to the proper level. Refer to Master Cylinder Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). Rear Brake Caliper Bracket Replacement Rear Brake Caliper Bracket Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Note: Remove and discard the brake caliper pin bolts. 3. Remove the brake caliper from the brake caliper bracket (3) and support the brake caliper with heavy mechanic's wire, or equivalent. Do NOT disconnect the hydraulic brake flexible hose from the caliper. Refer to Rear Brake Caliper Replacement (with Dampener) (See: Rear Brake Caliper Replacement (with Dampener)). 4. Remove the brake pads from the brake caliper bracket (3). 5. Remove the brake pad retainers from the brake caliper bracket. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4026 Note: Discard the brake caliper bracket bolts. 6. Remove the brake caliper bracket bolts (1). 7. Remove the rear brake caliper bracket. 8. Inspect the brake mounting and hardware. Refer to Rear Brake Caliper Hardware Replacement (See: Rear Brake Caliper Hardware Replacement ). 9. Inspect the brake caliper bracket. 10. Replace the brake caliper bracket if cracked or damaged. Installation Procedure 1. Install the brake caliper bracket. Caution: This is a self-retaining fastener joint that does not require thread locking compounds. Do not attempt to clean the threads with a standard tap. If a standard tap is used, damage to the joint threads will occur. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the NEW brake caliper mounting bracket bolts (1) and tighten to 100 Nm (74 lb ft) + 60° 75°. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4027 3. Install the brake pad retainers (2) to the brake caliper bracket (3). 4. Install the brake pads (1) to the brake caliper bracket. 5. Install the brake caliper. Refer to Rear Brake Caliper Replacement (with Dampener) (See: Rear Brake Caliper Replacement (with Dampener)). 6. Install the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 7. Lower the vehicle. 8. Pump the brake pedal 2-3 times in order to seat the rear disc brake pads to the rotor. Rear Brake Caliper Replacement (with Dampener) Rear Brake Caliper Replacement (with Dampener) Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4028 6. Remove the brake hose to caliper bolt (2) from the brake caliper. 7. Remove the brake hose (1) from the brake caliper. 8. Remove and discard the 2 copper brake hose gaskets (3). These gaskets may be stuck to the brake caliper and/or the brake hose end. 9. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination. 10. Remove the upper brake caliper pin bolt (1). 11. Remove the brake caliper vibration dampener (3). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4029 12. Remove the park brake cable from the rear parking brake lever (1). 13. Remove the brake caliper from the brake caliper bracket. Installation Procedure 1. Inspect the caliper slide boots for cuts, tears, or deterioration. If damaged, replace the slides and boots. Refer to Rear Brake Caliper Hardware Replacement (See: Rear Brake Caliper Hardware Replacement). 2. Install the brake caliper to the brake caliper bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the lower brake caliper pin bolt (1) and tighten to 28 Nm (20 lb ft). 4. Install the brake caliper vibration dampener (3) and tighten to 28 Nm (20 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4030 5. Install the park brake cable to the rear parking brake lever (1). 6. Remove the caps or plugs from the brake caliper opening and the brake hose. Note: DO NOT reuse the copper brake hose gaskets. 7. Install NEW copper brake hose gaskets (3) to the brake hose-to-caliper bolt (2) and to the brake hose. 8. Install the brake hose and the brake hose-to-caliper bolt to the brake caliper and tighten the bolt to 40 Nm (30 lb ft). 9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Pressure)). 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 9 and 10 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 13. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 14. Lower the vehicle. 15. Apply and release the park brake lever 4 times. Rear Brake Caliper Vibration Dampener Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4031 Rear Brake Caliper Vibration Dampener Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Open the cap (2) of the brake caliper vibration damper (1), to gain access to the internal torx. 4. Remove the brake caliper vibration damper (2) from the brake caliper vibration damper stud (1). Hold against internal torx of damper stud (1). 5. Remove the damper stud (1) from the rear brake. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4032 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the damper stud (1) to the rear brake and tighten to 28 Nm (21 lb ft). 2. Attach the brake caliper vibration damper (2) to the stud (1) by turn in 2 threads ONLY. 3. Tighten the brake caliper vibration damper (2) to 9 Nm (80 lb in) with a suitable tool. 4. Close the cap (2) of the brake caliper vibration damper (1). 5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) 6. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4033 Brake Caliper: Overhaul Front Brake Caliper Overhaul Disassembly Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Warning Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury. Caution: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. 1. Remove the brake caliper from the vehicle. Refer to Front Brake Caliper Replacement (See: Removal and Replacement/Front Brake Caliper Replacement). 2. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the caliper (1) through the fluid inlet hole. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4034 3. Remove the piston dust boot seal (1) from the seal counterbore in the caliper (4). Discard the boot seal. 4. Using a small wooden or plastic tool, remove the piston seal (3) from the caliper bore. Discard the piston seal. 5. Remove the bleeder valve cap (6). 6. Remove the bleeder valve (5). Note: Do not use abrasives to clean the brake caliper piston. 7. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 8. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 9. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent. 10. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered, compressed air. 11. Inspect the caliper piston for cracks, scoring, and/or damage to the plating. Replace the caliper piston if any of these conditions exist. 12. Inspect the caliper mounting holes for cracks, scoring, pitting, rust and/or excessive corrosion. Replace the caliper assembly if any of these conditions exist. Assembly Procedure 1. Lubricate the new piston seal (3) with brake fluid from a clean, sealed brake fluid container. Refer to Adhesives, Fluids, Lubricants, and Sealers ( Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4035 See: Specifications/Fluid Type Specifications) for the recommended brake fluid. 2. Install the lubricated, new piston seal (3) into the caliper bore. 3. Apply a thin coat of brake fluid from a clean, sealed brake fluid container. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications) for the recommended brake fluid. 4. Install the bottom half of the caliper piston (2) into the caliper bore. 5. Install the new piston dust boot seal (1) over the caliper piston (2). 6. Compress the caliper piston (2) to the bottom of the caliper bore. 7. Fully seat the piston dust boot seal (1) into caliper counterbore. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the bleeder valve to the caliper and tighten the valve to 17 Nm (13 lb ft). 9. Install the bleeder valve cap. 10. Install the brake caliper to the vehicle. Refer to Front Brake Caliper Replacement (See: Removal and Replacement/Front Brake Caliper Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Brake pads - front and rear Minimum Thickness ............................................................................................................................. ....................................................... 2.0 mm (0.08 in) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 4039 Brake Pad: Testing and Inspection Brake Pad Inspection Special Tools CH-230-A - Disc Gauge For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Remove brake pads. Refer to Front Disc Brake Pads Replacement (See: Service and Repair/Removal and Replacement/Front Disc Brake Pads Replacement) and/or Rear Disc Brake Pads Replacement (See: Service and Repair/Removal and Replacement/Rear Disc Brake Pads Replacement). 2. Measure remaining brake pad thickness at several points, using the CH-230-A - disc gauge (1). 3. Compare brake pad thickness to disc brake component specifications. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures Brake Pad: Procedures Brake Pad and Rotor Burnishing Warning Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Note: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 4042 Brake Pad: Removal and Replacement Front Disc Brake Pads Replacement Front Disc Brake Pads Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 6. Remove the brake caliper lower guide pin bolt (2). 7. Without disconnecting the hydraulic brake flexible hose, pivot the caliper (1) upward and secure the caliper with heavy mechanics wire, or equivalent. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 4043 8. Remove the brake pads (1) from the caliper mounting bracket. 9. Push the disc brake caliper piston (1) into the caliper bore using a disc brake piston installation tool. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 4044 10. Remove the brake pad retainer springs (1) from the caliper bracket. 11. Thoroughly clean the brake pad hardware mating surfaces of the caliper bracket of any debris and corrosion. 12. Inspect the brake caliper guide pins for freedom of movement and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: * Restricted caliper guide pin movement * Looseness in the brake caliper mounting bracket * Seized or binding caliper guide pins * Split or torn boots 13. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement. Installation Procedure 1. Ensure the brake pad hardware mating surfaces are clean. 2. Install the brake pad retainer springs (1) to the brake caliper bracket. Apply a thin coat of high temperature silicone lube to the brake pad retainers. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 4045 Note: The wear sensor equipped disc brake pad must be mounted inboard of the rotor with the leading edge of the sensor facing the brake rotor during forward wheel rotation, or at the top of the pad when installed in vehicle position. 3. Install the brake pads (1) to the caliper bracket. 4. Remove the support, and rotate the brake caliper into position over the disc brake pads and to the caliper mounting bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the lower brake caliper guide pin bolt and tighten to 28 Nm (21 lb ft). 6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 7. Lower the vehicle. 8. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance. 9. Slowly release the brake pedal. 10. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads. 11. Fill the master cylinder auxiliary reservoir to the proper level. Refer to Master Cylinder Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). Rear Disc Brake Pads Replacement Rear Disc Brake Pads Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 4046 6. Remove the brake caliper mass dampener (2). Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 7. Without disconnecting the hydraulic brake flexible hose, pivot the caliper (1) upward and secure the caliper with heavy mechanics wire, or equivalent. Mark the brake caliper piston position to the brake caliper (1). 8. Remove the brake pads (1) from the caliper mounting bracket (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 4047 9. Remove the brake pad retainer springs (1) from the caliper bracket (2). 10. Thoroughly clean the brake pad hardware mating surfaces of the caliper bracket, of any debris and corrosion. 11. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: * Restricted caliper guide pin movement * Looseness in the brake caliper mounting bracket * Seized or binding caliper guide pins * Split or torn boots. 12. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement. Installation Procedure 1. Ensure the brake pad hardware mating surfaces are clean. 2. Install the brake pad retainers springs (1) to the brake caliper bracket (2) and apply a thin coat of high temperature silicone lube to the brake pad retainers. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 4048 Note: The wear sensor equipped disc brake pad must be mounted inboard of the rotor with the leading edge of the sensor facing the brake rotor during forward wheel rotation, or at the top of the pad when installed in vehicle position. 3. Install the brake pads (1) to the caliper bracket (2). 4. Rotate the brake caliper piston (1) into the brake caliper bore. 5. Align the notch on the brake caliper piston with the pin (2) on the disc brake pad. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 4049 6. Remove the support, and rotate the brake caliper (1) into position over the disc brake pads and to the caliper mounting bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the lower brake caliper mass dampener (2) and tighten to 28 Nm (21 lb ft). 8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads. 13. Fill the master cylinder reservoir to the proper level. Refer to Master Cylinder Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Front Brakes Rotor Minimum Allowable Thickness After Refinish (15" Brake System)................................................................................................23.2 mm (0.913 in) Rotor Discard Thickness* (15" Brake System)............................................................................................... ..............................................23 mm (0.905 in) Rotor Maximum Allowable Assembled Lateral Runout (15" Brake System)............................................................................................0.05 mm (0.002 in) Rotor Maximum Allowable Thickness Variation (15" Brake System)...................................................................................................0.006 mm (0.0002 in) Rear Brakes Rotor Minimum Allowable Thickness After Refinish (15" Brake System)................................................................................................10.2 mm (0.402 in) Rotor Discard Thickness* (15" Brake System)............................................................................................... ..............................................10 mm (0.393 in) Rotor Maximum Allowable Assembled Lateral Runout (15" Brake System)............................................................................................0.05 mm (0.002 in) Rotor Maximum Allowable Thickness Variation (15" Brake System)...................................................................................................0.006 mm (0.0002 in) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction Brake Rotor Assembled Lateral Runout Correction Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). * Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). Review the following acceptable methods for bringing the brake rotor assembled LRO to within specifications. Determine which method to use for the specific vehicle being repaired. * The indexing method of correcting assembled LRO is most effective when the LRO specification is only exceeded by a relatively small amount: 0.025-0.127 mm (0.001-0.005 in). Indexing is used to achieve the best possible match of high spots to low spots between related components. Refer to Brake Rotor Assembled Lateral Runout Correction - Indexing (See: Brake Rotor Assembled Lateral Runout Correction - Indexing). * The correction plate method of correcting assembled LRO involves the addition of a tapered plate between the brake rotor and the hub/axle flange. The correction plate method can be used to correct LRO that exceeds the specification by up to 0.23 mm (0.009 in). Refer to Brake Rotor Assembled Lateral Runout Correction - Correction Plates (See: Brake Rotor Assembled Lateral Runout Correction - Correction Plates). * The on-vehicle brake lathe method is used to bring the LRO to within specifications through compensating for LRO while refinishing the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe (See: Brake Rotor Assembled Lateral Runout Correction On Vehicle Lathe). If the assembled LRO cannot be corrected using these methods, then other components must be suspected as causing and/or contributing to the LRO concern. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 4055 Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction Correction Plates Brake Rotor Assembled Lateral Runout Correction - Correction Plates Special Tools CH 45101-100 - Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Measurement (See: Brake Rotor Thickness Measurement). * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 1. Rotate the brake rotor to position the high spot, identified and marked during the brake rotor assembled LRO measurement procedure, to face upward. 2. Remove the CH 45101-100 - washers and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure. 3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 4. Select the correction plate, following the manufacturer's instructions, which has a specification closest to the assembled LRO measurement. For example: If the assembled LRO measurement was 0.076 mm (0.003 in), the 0.076 mm (0.003 in) correction plate would be used. If the measurement was 0.127 mm (0.005 in), the 0.152 mm (0.006 in) correction plate would be used. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 4056 5. Determine the positioning for the correction plate (1) using the high spot mark (3) made during the brake rotor assembled LRO measurement procedure. Note: * Do NOT install used correction plates in an attempt to correct brake rotor assembled LRO. * Do NOT stack up, or install more than one correction plate onto one hub/axle flange location, in an attempt to correct brake rotor assembled LRO. 6. Install the correction plate (1) onto the hub/axle flange, with the V-shaped notch (2) orientated to align with the high spot mark (3), that was positioned to face upward. 7. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for proper orientation to the flange. 8. Hold the rotor firmly in place against the hub/axle flange and install one of the CH-45101-100 - washers (1) and one lug nut (2) onto the upper-most wheel stud. 9. Continue to hold the rotor secure and tighten the lug nut firmly by hand. 10. Install the remaining CH 45101-100 - washers (1) and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 11. Tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation ( Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 4057 See: Maintenance/Wheels and Tires/Service and Repair). 12. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH 45101-100 - washers and the lug nuts. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 4058 Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction Indexing Brake Rotor Assembled Lateral Runout Correction - Indexing Special Tools CH 45101-100 - Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Measurement (See: Brake Rotor Thickness Measurement). * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800 - 11 300 km (3,000 - 7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 1. Remove the CH 45101-100 - washers and the lug nuts that were installed during the assembled LRO measurement procedure. 2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 3. Index the brake rotor in a different orientation to the hub/axle flange. 4. Hold the rotor firmly in place against the hub/axle flange and install one of the CH 45101-100 - washers (1) and one lug nut (2) onto the upper-most wheel stud. 5. Continue to hold the rotor secure and tighten the lug nut firmly by hand. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 4059 6. Install the remaining CH 45101-100 - washers (1) and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 7. Tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation ( See: Maintenance/Wheels and Tires/Service and Repair). 8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 9. Compare the amount of change between this measurement and the original measurement. 10. If this measurement is within specifications, proceed to step 14. 11. If this measurement still exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained. 12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it was originally. 13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH 45101-100 - washers and the lug nuts. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 4060 Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Special Tools CH 45101-100 - Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Measurement (See: Brake Rotor Thickness Measurement). * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 1. Ensure that the caliper and caliper bracket that are already being supported, are clear from contacting any rotating components, such as the brake rotor. 2. Remove the CH 45101-100 - washers and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure. 3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 4. Set up the lathe, following the manufacturer's instructions. 5. Refinish the brake rotor, following the brake lathe manufacturer's instructions. Refer to Brake Rotor Refinishing (See: Service and Repair/Procedures/Brake Rotor Refinishing). 6. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement (See: Brake Rotor Thickness Measurement). 7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. After replacing the rotor, proceed to step 10. 8. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish. 2. Using moderate pressure, apply the non-directional finish: * If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum oxide sandpaper. * If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150-grit aluminum oxide sandpaper. 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 9. Remove the lathe from the vehicle. 10. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 12. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH 45101-100 - washers and the lug nuts. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 4061 Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction Brake Rotor Assembled Lateral Runout Correction Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). * Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). Review the following acceptable methods for bringing the brake rotor assembled LRO to within specifications. Determine which method to use for the specific vehicle being repaired. * The indexing method of correcting assembled LRO is most effective when the LRO specification is only exceeded by a relatively small amount: 0.025-0.127 mm (0.001-0.005 in). Indexing is used to achieve the best possible match of high spots to low spots between related components. Refer to Brake Rotor Assembled Lateral Runout Correction - Indexing (See: Brake Rotor Assembled Lateral Runout Correction - Indexing). * The correction plate method of correcting assembled LRO involves the addition of a tapered plate between the brake rotor and the hub/axle flange. The correction plate method can be used to correct LRO that exceeds the specification by up to 0.23 mm (0.009 in). Refer to Brake Rotor Assembled Lateral Runout Correction - Correction Plates (See: Brake Rotor Assembled Lateral Runout Correction - Correction Plates). * The on-vehicle brake lathe method is used to bring the LRO to within specifications through compensating for LRO while refinishing the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe (See: Brake Rotor Assembled Lateral Runout Correction On Vehicle Lathe). If the assembled LRO cannot be corrected using these methods, then other components must be suspected as causing and/or contributing to the LRO concern. Brake Rotor Assembled Lateral Runout Correction - Correction Plates Brake Rotor Assembled Lateral Runout Correction - Correction Plates Special Tools CH 45101-100 - Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Measurement (See: Brake Rotor Thickness Measurement). * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 4062 1. Rotate the brake rotor to position the high spot, identified and marked during the brake rotor assembled LRO measurement procedure, to face upward. 2. Remove the CH 45101-100 - washers and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure. 3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 4. Select the correction plate, following the manufacturer's instructions, which has a specification closest to the assembled LRO measurement. For example: If the assembled LRO measurement was 0.076 mm (0.003 in), the 0.076 mm (0.003 in) correction plate would be used. If the measurement was 0.127 mm (0.005 in), the 0.152 mm (0.006 in) correction plate would be used. 5. Determine the positioning for the correction plate (1) using the high spot mark (3) made during the brake rotor assembled LRO measurement procedure. Note: * Do NOT install used correction plates in an attempt to correct brake rotor assembled LRO. * Do NOT stack up, or install more than one correction plate onto one hub/axle flange location, in an attempt to correct brake rotor assembled LRO. 6. Install the correction plate (1) onto the hub/axle flange, with the V-shaped notch (2) orientated to align with the high spot mark (3), that was positioned to face upward. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 4063 7. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for proper orientation to the flange. 8. Hold the rotor firmly in place against the hub/axle flange and install one of the CH-45101-100 - washers (1) and one lug nut (2) onto the upper-most wheel stud. 9. Continue to hold the rotor secure and tighten the lug nut firmly by hand. 10. Install the remaining CH 45101-100 - washers (1) and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 11. Tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation ( See: Maintenance/Wheels and Tires/Service and Repair). 12. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH 45101-100 - washers and the lug nuts. Brake Rotor Assembled Lateral Runout Correction - Indexing Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 4064 Brake Rotor Assembled Lateral Runout Correction - Indexing Special Tools CH 45101-100 - Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Measurement (See: Brake Rotor Thickness Measurement). * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800 - 11 300 km (3,000 - 7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 1. Remove the CH 45101-100 - washers and the lug nuts that were installed during the assembled LRO measurement procedure. 2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 3. Index the brake rotor in a different orientation to the hub/axle flange. 4. Hold the rotor firmly in place against the hub/axle flange and install one of the CH 45101-100 - washers (1) and one lug nut (2) onto the upper-most wheel stud. 5. Continue to hold the rotor secure and tighten the lug nut firmly by hand. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 4065 6. Install the remaining CH 45101-100 - washers (1) and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 7. Tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation ( See: Maintenance/Wheels and Tires/Service and Repair). 8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 9. Compare the amount of change between this measurement and the original measurement. 10. If this measurement is within specifications, proceed to step 14. 11. If this measurement still exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained. 12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it was originally. 13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH 45101-100 - washers and the lug nuts. Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Special Tools CH 45101-100 - Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Measurement (See: Brake Rotor Thickness Measurement). * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 1. Ensure that the caliper and caliper bracket that are already being supported, are clear from contacting any rotating components, such as the brake rotor. 2. Remove the CH 45101-100 - washers and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure. 3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 4. Set up the lathe, following the manufacturer's instructions. 5. Refinish the brake rotor, following the brake lathe manufacturer's instructions. Refer to Brake Rotor Refinishing (See: Service and Repair/Procedures/Brake Rotor Refinishing). 6. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement (See: Brake Rotor Thickness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 4066 Measurement). 7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. After replacing the rotor, proceed to step 10. 8. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish. 2. Using moderate pressure, apply the non-directional finish: * If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum oxide sandpaper. * If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150-grit aluminum oxide sandpaper. 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 9. Remove the lathe from the vehicle. 10. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 12. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH 45101-100 - washers and the lug nuts. Brake Rotor Assembled Lateral Runout Measurement Brake Rotor Assembled Lateral Runout Measurement Special Tools * CH-39544-KIT - Complete Torque Socket Set - 10 PCS , or equivalent * CH-41013 - Rotor Resurfacing Kit * CH-42450-A - Wheel Hub Resurfacing Kit * CH-45101 - Hub and Wheel Runout Gauge * CH-45101-100 - Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11,300 km (3,000-7,000 mi). * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). 1. Matchmark the position of the brake rotor to the wheel studs if this has not been done already. Note: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. 2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles, corrosion, rust, or debris remaining. If the wheel hub/axle flange and/or if the brake rotor mating surfaces exhibit these conditions, perform the following steps: 1. Remove the brake rotor from the vehicle. Refer to Front Brake Rotor Replacement (See: Service and Repair/Removal and Replacement/Front Brake Rotor Replacement) and/or Rear Brake Rotor Replacement (See: Service and Repair/Removal and Replacement/Rear Brake Rotor Replacement). 2. Using the CH-42450-A - wheel hub resurfacing kit , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 3. Using the CH-41013 - rotor resurfacing kit , thoroughly clean any rust or corrosion from the mating surface of the brake rotor. 4. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Install the rotor to the hub/axle flange using the matchmark made prior to removal. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 4067 4. Hold the rotor firmly in place against the hub/axle flange and install one of the CH-45101-100 conical brake rotor washers (1), and one lug nut (2) onto the upper-most wheel stud. 5. Continue to hold the rotor secure and tighten the lug nut firmly by hand. 6. Install the remaining CH-45101-100 - conical brake rotor washers and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 7. Using the CH-39544-KIT - complete torque socket set - 10 pcs , or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 8. If the brake rotor has been REFINISHED or REPLACED with a new rotor, proceed to step 14. 9. If the brake rotor meets the following criteria, proceed to step 10. * The rotor is within specifications and is being REUSED. * The rotor has NOT been refinished. * The rotor does NOT exhibit thickness variation exceeding the maximum allowable level. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 4068 10. Mount a dial indicator, CH-45101 - hub and wheel runout gauge , or equivalent, to the steering knuckle and position the indicator button so it contacts the brake rotor friction surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor. 11. Measure and record the assembled LRO of the brake rotor. 1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero. 2. Rotate the rotor until the highest reading is displayed on the dial. 3. Mark the location of the high spot relative to the nearest wheel stud, or studs. 4. Measure and record the amount of LRO. 12. Compare the brake rotor assembled LRO to the following specification: * Front brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) * Rear brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) 13. If the brake rotor assembled LRO is within specifications, proceed to step 18. If the brake rotor assembled LRO exceeds the specification, refinish the rotor to ensure true parallelism. Refer to Brake Rotor Refinishing (See: Service and Repair/Procedures/Brake Rotor Refinishing). After refinishing the rotor, proceed to step 14. 14. Mount a dial indicator, CH-45101 - hub and wheel runout gauge , or equivalent, to the steering knuckle and position the indicator button so it contacts the brake rotor friction surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor. 15. Measure and record the assembled LRO of the brake rotor. 1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero. 2. Rotate the rotor until the highest reading is displayed on the dial. 3. Mark the location of the high spot relative to the nearest wheel stud, or studs. 4. Measure and record the amount of LRO. 16. Compare the brake rotor assembled LRO to the following specification: * Front brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) * Rear brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) 17. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 18. If the brake rotor assembled LRO measurement is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH-45101-100 - conical brake rotor washers and the lug nuts. Brake Rotor Surface and Wear Inspection Brake Rotor Surface and Wear Inspection Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 4069 1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to Front Disc Brake Pads Replacement (See: Brake Pad/Service and Repair/Removal and Replacement/Front Disc Brake Pads Replacement) or/and Rear Disc Brake Pads Replacement (See: Brake Pad/Service and Repair/Removal and Replacement/Rear Disc Brake Pads Replacement). 2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Inspect the friction surfaces of the brake rotor for the following Braking Surface Conditions: * Heavy rust and/or pitting. * Light surface rust can be removed with an abrasive disc. Heavy surface rust and/or pitting must be removed by refinishing the rotor. Refer to Brake Rotor Refinishing (See: Service and Repair/Procedures/Brake Rotor Refinishing). * Cracks and/or heat spots. * Excessive blueing discoloration. 4. If the friction surfaces of the brake rotor exhibit one or more of the Braking Surface Conditions, the rotor requires refinishing or replacement. Refer to Front Brake Rotor Replacement (See: Service and Repair/Removal and Replacement/Front Brake Rotor Replacement) , Rear Brake Rotor Replacement (See: Service and Repair/Removal and Replacement/Rear Brake Rotor Replacement) or Brake Rotor Refinishing (See: Service and Repair/Procedures/Brake Rotor Refinishing). 5. Using an appropriate tool (1) for measurement, calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch, measure and record the scoring depth of any grooves present on the rotor friction surfaces. 6. Compare the groove scoring depth recorded disc brake component Specifications. 7. If the brake rotor scoring depth exceeds the specification, or if an excessive amount of scoring is present, the rotor requires refinishing or replacement. Refer to Front Brake Rotor Replacement (See: Service and Repair/Removal and Replacement/Front Brake Rotor Replacement) , Rear Brake Rotor Replacement (See: Service and Repair/Removal and Replacement/Rear Brake Rotor Replacement) or Brake Rotor Refinishing (See: Service and Repair/Procedures/Brake Rotor Refinishing). Brake Rotor Thickness Measurement Brake Rotor Thickness Measurement Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 4070 1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to Front Disc Brake Pads Replacement (See: Brake Pad/Service and Repair/Removal and Replacement/Front Disc Brake Pads Replacement) and/or Rear Disc Brake Pads Replacement (See: Brake Pad/Service and Repair/Removal and Replacement/Rear Disc Brake Pads Replacement) , if equipped. 2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Using a micrometer (1) calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch, measure and record the lowest thickness of the brake rotor at 4 or more points, equally spaced around the rotor. Ensure that the measurements are only taken within the friction surfaces and that the micrometer is positioned the same distance from the outside edge of the rotor, about 13 mm (0.5 in), for each measurement. 4. Compare the lowest thickness measurement to the disc brake component specifications. 5. If the lowest thickness measurement of the brake rotor is above the minimum allowable thickness after refinishing specification, the rotor may be able to be refinished, depending upon surface and wear conditions which may be present. 6. If the lowest thickness measurement of the brake rotor is at or below the minimum allowable thickness after refinishing specification, the rotor may not be refinished. 7. If the lowest thickness measurement of the brake rotor is at or below the discard thickness specification, the rotor requires replacement. Refer to Front Brake Rotor Replacement (See: Service and Repair/Removal and Replacement/Front Brake Rotor Replacement) and/or Rear Brake Rotor Replacement (See: Service and Repair/Removal and Replacement/Rear Brake Rotor Replacement). Brake Rotor Thickness Variation Measurement Brake Rotor Thickness Variation Measurement Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: Any disc brake rotor that exhibits thickness variation exceeding the maximum acceptable level must be refinished or replaced. Thickness variation exceeding the maximum acceptable level can cause brake pulsation. 1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to Front Disc Brake Pads Replacement (See: Brake Pad/Service and Repair/Removal and Replacement/Front Disc Brake Pads Replacement) and/or Rear Disc Brake Pads Replacement (See: Brake Pad/Service and Repair/Removal and Replacement/Rear Disc Brake Pads Replacement) , if equipped. 2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 4071 3. Using a micrometer (1) calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch, measure and record the thickness of the brake rotor at 4 or more points, evenly spaced around the rotor. Ensure that the measurements are only taken within the friction surfaces and that the micrometer is positioned the same distance from the outer edge of the rotor, about 13 mm (0.5 in), for each measurement. Calculate the difference between the 4. Calculate the difference between the highest and lowest thickness measurements recorded to obtain the amount of thickness variation. 5. Compare the thickness variation measurement to the disc brake component specifications. Note: Whenever a brake rotor is refinished or replaced, the assembled lateral runout (LRO) of the rotor must be measured to ensure optimum performance of the disc brakes. 6. If the brake rotor thickness variation measurement exceeds the specification, the rotor requires refinishing or replacement. Refer to Front Brake Rotor Replacement (See: Service and Repair/Removal and Replacement/Front Brake Rotor Replacement) , Rear Brake Rotor Replacement ( See: Service and Repair/Removal and Replacement/Rear Brake Rotor Replacement) or Brake Rotor Refinishing (See: Service and Repair/Procedures/Brake Rotor Refinishing). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures Brake Rotor/Disc: Procedures Brake Pad and Rotor Burnishing Brake Pad and Rotor Burnishing Warning Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Note: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Brake Rotor Refinishing Brake Rotor Refinishing Special Tools * CH 41013 - Rotor Resurfacing Kit * CH 42450-A - Wheel Hub Resurfacing Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * The disc brake rotors do not require refinishing as part of routine brake system service. New disc brake rotors do not require refinishing. Do not refinish disc brake rotors in an attempt to correct the following conditions: - Brake system noise - squeal, growl, groan - Uneven and/or premature disc brake pad wear - Superficial or cosmetic corrosion/rust of the disc brake rotor friction surface - Scoring of the disc brake rotor friction surface less than the maximum allowable specification * Before refinishing a brake rotor, the rotor MUST first be checked for adequate thickness to allow the rotor to be refinished and remain above the minimum allowable thickness after refinish specification. Refer to Brake Rotor Thickness Measurement (See: Testing and Inspection/Brake Rotor Thickness Measurement). Disc brake rotors should only be refinished if they have adequate thickness to be refinished and if one or more of the following conditions exist: - Thickness variation in excess of the maximum allowable specification - Excessive corrosion/rust and/or pitting - Cracks and/or heat spots - Excessive blueing discoloration - Scoring of the disc brake rotor surface in excess of the maximum allowable specification * Disc brake rotors may need to be refinished as part of the process for correcting brake rotor assembled lateral runout (LRO) that exceeds the maximum allowable specification. Note: If the vehicle is equipped with cross-drilled rotors, use a lathe with positive rake tooling. This setup requires less cutting pressure, which will result in less vibration, and a better surface finish. Also, use a vibration dampener when cutting. Otherwise, refinish according to the following instructions. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 4074 Note: Whenever the brake rotor has been separated from the hub/axle flange, clean any rust or contaminants from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in increased assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. 1. Using the CH 42450-A - kit , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 2. Using the CH 41013 - kit , thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Mount the brake rotor to the brake lathe according to the lathe manufacturer's instructions, ensuring that all mounting attachments and adapters are clean and free of debris. 5. Ensure that any vibration dampening attachments are securely in place. 6. With the brake lathe running, slowly bring in the cutting tools until they just contact the brake rotor friction surfaces. 7. Observe the witness mark on the brake rotor. If the witness mark extends approximately three-quarters or more of the way around the brake rotor friction surface on each side, the brake rotor is properly mounted to the lathe. 8. If the witness mark does not extend three-quarters or more of the way around the brake rotor, re-mount the rotor to the lathe. 9. Following the brake lathe manufacturer's instructions, refinish the brake rotor. 10. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement (See: Testing and Inspection/Brake Rotor Thickness Measurement). 11. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. Refer to Front Brake Rotor Replacement (See: Removal and Replacement/Front Brake Rotor Replacement) and/or Rear Brake Rotor Replacement (See: Removal and Replacement/Rear Brake Rotor Replacement). 12. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish. 2. Using moderate pressure, apply the non-directional finish: * If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum oxide sandpaper. * If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150-grit aluminum oxide sandpaper. 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 13. Remove the brake rotor from the brake lathe. 14. Measure the assembled LRO of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Testing and Inspection/Brake Rotor Assembled Lateral Runout Measurement). 15. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout Correction (See: Testing and Inspection/Brake Rotor Assembled Lateral Runout Correction). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 4075 Brake Rotor/Disc: Removal and Replacement Front Brake Rotor Replacement Front Brake Rotor Replacement Special Tools * CH-41013 - Rotor Resurfacing Kit * CH-42450-A - Wheel Hub Resurfacing Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Install a C-clamp (1) over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 4. Tighten the C-clamp (1) until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor. 5. Remove the C-clamp (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 4076 6. Remove and DISCARD the brake caliper bracket bolts (1). Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Note: Do NOT disconnect the hydraulic brake flexible hose from the caliper. 7. Remove the brake caliper and the caliper mounting bracket as an assembly (1) from the steering knuckle and support the assembly with heavy mechanic's wire, or equivalent. Ensure that there is no tension on the hydraulic brake flexible hose. 8. Mark the position of the brake rotor to the wheel studs. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 4077 9. Remove the brake rotor screw (2). 10. Remove the brake rotor (1) from the wheel hub. Installation Procedure Note: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. 1. Using the CH 42450-A - resurfacer , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange (1). 2. Using the CH 41013 - resurfacer , thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor (2). 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Install the brake rotor to the hub/axle flange. Use the mark made prior to removal to ensure proper orientation to the flange. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the brake rotor screw and tighten to 7 Nm (62 lb in). 6. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled LRO of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Testing and Inspection/Brake Rotor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 4078 Assembled Lateral Runout Measurement). 7. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout Correction (See: Testing and Inspection/Brake Rotor Assembled Lateral Runout Correction). 8. Remove the support, and install the brake caliper and the brake caliper bracket as an assembly to the steering knuckle. 9. Install NEW brake caliper bracket bolts (1) and tighten to 100 Nm (74 lb ft) + 60° + 15°. 10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 11. Lower the vehicle. Rear Brake Rotor Replacement Rear Brake Rotor Replacement Special Tools * CH 41013 - Rotor Resurfacing Kit * CH 42450-A - Wheel Hub Resurfacing Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 4079 Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Remove rear brake caliper bracket. Refer to Rear Brake Caliper Bracket Replacement (See: Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement) 2. Matchmark the position of the brake rotor to the wheel studs. 3. Remove the rear brake rotor bolt (2). 4. Remove rear brake rotor (1) from the wheel hub. Installation Procedure 1. Using the CH 42450-A - kit , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 2. Using the CH 41013 - kit , thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Install the brake rotor (1) to the hub/axle flange. Use the matchmark made prior to removal for proper orientation to the flange. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install rear brake rotor bolt (2) and tighten to 7 Nm (62 lb in). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 4080 6. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled LRO of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Testing and Inspection/Brake Rotor Assembled Lateral Runout Measurement). 7. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout Correction (See: Testing and Inspection/Brake Rotor Assembled Lateral Runout Correction). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair Backing Plate: Service and Repair Rear Brake Backing Plate Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the brake drum. Refer to Brake Drum Replacement (See: Brake Drum/Service and Repair/Removal and Replacement). 4. Remove the brake shoes. Refer to Brake Shoe Replacement (See: Brake Shoe/Service and Repair). 5. Remove the wheel cylinder. Refer to Rear Brake Cylinder Replacement (See: Wheel Cylinder/Service and Repair). 6. Release the rear park brake cable end fitting (1) from the drum brake backing plate. 7. Remove the wheel bearing/hub assembly. Refer to Rear Wheel Bearing and Hub Replacement (Disc Brakes) (See: Maintenance/Wheels and Tires/Wheel Hub/Service and Repair/Rear Suspension) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Page 4085 8. Remove the brake backing plate (1). Installation Procedure 1. Install the brake backing plate (1). 2. Install the wheel bearing/hub assembly. Refer to Rear Wheel Bearing and Hub Replacement (Disc Brakes) (See: Maintenance/Wheels and Tires/Wheel Hub/Service and Repair/Rear Suspension) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Page 4086 3. Secure the rear park brake cable end fitting (1) to the brake backing plate. 4. Install the wheel cylinder. Refer to Rear Brake Cylinder Replacement (See: Wheel Cylinder/Service and Repair). 5. Install the brake shoes. Refer to Brake Shoe Replacement (See: Brake Shoe/Service and Repair). 6. Adjust the drum brakes. Refer to Drum Brake Adjustment (See: Adjustments). 7. Install the brake drum. Refer to Brake Drum Replacement (See: Brake Drum/Service and Repair/Removal and Replacement). 8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Pressure)). 9. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 10. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications Brake Drum Discard Diameter.............................................................................................................. ....................................................256 mm (10.078 in) Brake Drum Maximum Diameter After Refinish.......................................................................................................................................256 mm (10.078 in) Brake Drum Maximum Allowable Radial Runout.....................................................................................................................................0.05 mm (0.002 in) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Testing and Inspection > Brake Drum Diameter Measurement Brake Drum: Testing and Inspection Brake Drum Diameter Measurement Brake Drum Diameter Measurement Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Remove brake drum. Refer to Brake Drum Replacement (See: Service and Repair/Removal and Replacement) 2. Clean the brake shoe lining contact surface of the brake drum (2) with denatured alcohol or an equivalent approved brake cleaner. 3. Using a brake drum micrometer (1) calibrated in thousandths-of-an-inch, measure and record the largest diameter of the brake drum at four or more points, equally spaced around the drum. Ensure the measurements are only taken within the brake shoe lining contact area. The micrometer must be positioned the same distance from the outside edge of the drum for each measurement. 4. Compare the largest diameter measurement recorded to the brake drum component specifications. Refer to Drum Brake Component Specifications (See: Specifications). 5. If the largest diameter measurement of the brake drum is less than the maximum allowable inside diameter after refinishing specification; the drum may be refinished, depending upon surface and wear conditions. 6. If the largest diameter measurement of the brake drum is equal to or greater than the maximum allowable diameter after refinishing specification; the drum may not be refinished. 7. If the largest diameter measurement of the brake drum is equal to or greater than the discard diameter specification; the drum requires replacement. 8. Install brake drum. Refer to Brake Drum Replacement (See: Service and Repair/Removal and Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Testing and Inspection > Brake Drum Diameter Measurement > Page 4092 Brake Drum: Testing and Inspection Brake Drum Surface and Wear Inspection Brake Drum Surface and Wear Inspection Special Tools GE 572 - Dial Indicator For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Remove brake drum. Refer to Brake Drum Replacement (See: Service and Repair/Removal and Replacement). 2. Inspect the braking surface of the brake drum for the following braking surface conditions: * Heavy rust and/or pitting Light surface rust can be removed with an abrasive disc; heavy surface rust and/or pitting must be removed by refinishing the drum. * Cracks and/or heat spots * Excessive blueing discoloration * Missing balance weights * If the braking surface of the brake drum exhibits one or more of the Braking Surface Conditions listed, the drum requires refinishing or replacement. Refer to Brake Drum Replacement (See: Service and Repair/Removal and Replacement) or Rear Brake Drum Refinishing ( See: Service and Repair/Procedures). 3. Using a brake drum micrometer (1) calibrated in thousandths-of-an-inch, measure and record any grooves present on the drum braking surface. Ensure that the measurements are only taken within the brake shoe lining contact area. 4. Compare the groove, or scoring depth recorded to brake drum component specification. Refer to Drum Brake Component Specifications (See: Specifications). 5. If the brake drum scoring depth exceeds the specification, or if an excessive amount of scoring is present, the drum requires refinishing or replacement. Refer to Brake Drum Replacement (See: Service and Repair/Removal and Replacement) or Rear Brake Drum Refinishing (See: Service and Repair/Procedures). 6. Mount the brake drum on a brake lathe. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Testing and Inspection > Brake Drum Diameter Measurement > Page 4093 7. Mount a dial indicator, GE 572 - dial indicator (1) or equivalent, and position the indicator button so it contacts the braking surface of the brake drum (2) at a 90 degree angle, approximately 19 mm (0.75 in) from the outer edge of the drum. 8. Measure and record the radial runout of the brake drum. 1. Rotate the drum until the lowest reading is displayed on the indicator dial, then zero the dial. 2. Rotate the drum until the highest reading is displayed on the dial. 3. Compare the radial runout of the brake drum to the brake drum component specifications. Refer to Drum Brake Component Specifications ( See: Specifications). 4. If the brake drum radial runout exceeds the specification, the drum requires refinishing or replacement. Refer to Brake Drum Replacement ( See: Service and Repair/Removal and Replacement) or Rear Brake Drum Refinishing (See: Service and Repair/Procedures). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Procedures Brake Drum: Procedures Rear Brake Drum Refinishing Special Tools CH 41013 - Resurfacing Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: Do NOT refinish the brake drums in order to correct any of the following complaints: * Brake noise (growl/squeal) * Premature brake lining wear * Cosmetic or superficial corrosion of the drum braking surface * Drum discoloration Refinish the brake drums ONLY when one or more of the following conditions exist: * Severe scoring of the drum braking surface (groove depth in excess of 1 mm (0.039 in) * Brake pulsation caused by the following: - Brake drum out of round - Corrosion or pitting that is deeper than the drum braking surface 1. Use a micrometer in order to measure the largest diameter of the brake drum. If the largest diameter of the brake drum exceeds the brake drum maximum refinish diameter, do NOT refinish the brake drum. Replace the brake drum. 2. Use the CH 41013 - resurfacer in order to thoroughly clean the rust from the brake drum flange. 3. Refinish the brake drum. Refer to the brake lathe manufacturer's operating instructions. Note: Failure to obtain the best possible braking surface finish may cause the vehicle to stop with difficulty. 4. After machining the brake drum, use 120 grit aluminum oxide sandpaper in order to create a non-directional braking surface. Caution: Improperly tightened wheel bolts or nuts can lead to brake pulsation and rotor damage. In order to avoid expensive brake repairs, evenly tighten the wheel bolts or nuts to the proper torque specification. 5. Clean the braking surfaces with denatured alcohol or with a suitable brake cleaner. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Procedures > Page 4096 Brake Drum: Removal and Replacement Brake Drum Replacement Special Tools * CH 41013 - Rotor Resurfacing Kit * CH 42450-A - Wheel Hub Resurfacing Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Check to ensure that the park brake is fully released. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 4. Remove the brake drum screw (1). 5. Remove the brake drum (2). 6. If the brake drum is to be reinstalled to the vehicle, use the CH 41013 - resurfacer or equivalent to clean any rust or corrosion from the hub/flange mating surface of the brake drum (2). To clean any rust or corrosion from the hub/flange mating surface of the brake drum (2). 7. Use the CH 42450-A - resurfacer or equivalent to clean the wheel hub flange. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Procedures > Page 4097 1. If installing a new brake drum (2), use denatured alcohol or an equivalent approve brake cleaner and a clean shop towel to remove the protective coating from the friction surface of the drum. 2. Adjust the drum brakes. Refer to Drum Brake Adjustment (See: Adjustments). 3. Install the drum brake. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install drum brake screw (1) and tighten to 7 Nm (62 lb in). 5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 6. Lower the vehicle. 7. Apply the brakes approximately three times in order to seat and center the brake shoes within the drum. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: Specifications Brake Shoe Lining Minimum Thickness............................................................................................... .......................................................1.6 mm (0.063 in) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4101 Brake Shoe: Testing and Inspection Brake Shoe Inspection Special Tools CH 230 - Disc Gauge For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Measure the brake shoe lining thickness, using the CH 230 - gauge (1). 2. Compare the brake shoe lining thickness recorded to the brake drum component specification. Refer to Drum Brake Component Specifications ( See: Specifications). Note: Replace the shoe and lining assembly in axle sets only. 3. If the brake shoe lining thickness is less than the specification, or if a defect is found, replace the linings. Refer to Brake Shoe Replacement (See: Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4102 Brake Shoe: Service and Repair Brake Shoe Replacement Special Tools CH 346 - Mounting Tool For equivalent regional tool, refer to Special Tools (See: Tools and Equipment). Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the brake drum. Refer to Brake Drum Replacement (See: Brake Drum/Service and Repair/Removal and Replacement). Caution: Do not over stretch the adjuster spring. Damage can occur if the spring is over stretched. 4. Remove the adjuster spring (1). Disengage the adjuster spring hook end from the tab on the adjuster actuator lever, then release the spring from the brake shoe web hole. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4103 5. Release the adjuster actuator lever (1) from the adjuster assembly (2). Remove the adjuster assembly (2). 6. Remove the brake shoe springs (1), using the CH 346 - mounting tool to twist spring caps (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4104 7. Remove the brake shoes (1). Remove the lower spring (4) from front brake shoe. 8. Remove the parking brake cable (3) from the parking brake lever (2). Installation Procedure 1. Install the adjuster assembly (2) to the adjuster actuator lever (1). Turn in the adjuster as far as possible. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4105 2. Install the parking brake cable (3) to the parking brake lever (2). 3. Install the lower spring (4) to front brake shoe. 4. Install the brake shoes (1). 5. Install the brake shoe springs (1), using the CH 346 - mounting tool to twist spring caps. 6. Install the adjuster spring (1). Ensure that the loop end of the spring fully engages the tab on the actuator lever. 7. Install the brake drum. Refer to Brake Drum Replacement (See: Brake Drum/Service and Repair/Removal and Replacement). 8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) 9. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair Wheel Cylinder: Service and Repair Rear Brake Cylinder Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the brake drum. Refer to Brake Drum Replacement (See: Brake Drum/Service and Repair/Removal and Replacement). 4. Remove brake shoes. Refer to Brake Shoe Replacement (See: Brake Shoe/Service and Repair). 5. Clean any debris and contaminants from around the wheel cylinder. 6. Disconnect the brake pipe fitting (1) from the wheel cylinder. Cap the exposed brake pipe end to prevent fluid loss and 7. Remove the 2 wheel cylinder mounting bolts (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Page 4109 8. Remove the wheel cylinder (1) from the backing plate. Installation Procedure 1. Install the wheel cylinder (1) to backing plate. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Page 4110 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install wheel cylinder mounting bolts (2) and tighten to 10 Nm (89 lb in). 3. Connect the brake pipe fitting (1) at the wheel cylinder and tighten to 18 Nm (14 lb ft). 4. Install the brake shoes. Refer to Brake Shoe Replacement (See: Brake Shoe/Service and Repair). 5. Install the brake drum. Refer to Brake Drum Replacement (See: Brake Drum/Service and Repair/Removal and Replacement). 6. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Pressure)). 7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 8. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Antilock Brake System Automated Bleed Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Note: Before performing the ABS Automated Bleed Procedure, first perform a pressure bleed of the base brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Hydraulic Brake System Bleeding (Pressure)). The automated bleed procedure is recommended when one of the following conditions exist: * Base brake system bleeding does not achieve the desired pedal height or feel * Extreme loss of brake fluid has occurred * Air ingestion is suspected in the secondary circuits of the brake modulator assembly The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run the pump in order to purge any air from the secondary circuits. These circuits are normally closed off, and are only opened during system initialization at vehicle start up and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped in these circuits to flow out toward the brake corners. Performing the Automated Bleed Procedure Caution: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove all four tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Inspect the brake system for leaks and visual damage. Repair or replace components as needed. 4. Lower the vehicle. 5. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test). 6. Install a scan tool. 7. Turn the ignition ON, with the engine OFF. 8. With the scan tool, establish communications with the ABS system. Select Special Functions. Select Automated Bleed from the Special Functions menu. 9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 10. Following the directions given on the scan tool, pressure bleed the base brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Hydraulic Brake System Bleeding (Pressure)). 11. Follow the scan tool directions until the desired brake pedal height is achieved. 12. If the bleed procedure is aborted, a malfunction exists. Perform the following steps before resuming the bleed procedure: * If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) , and diagnose the appropriate DTC. * If the brake pedal feels spongy, perform the conventional brake bleed procedure again. Refer to Hydraulic Brake System Bleeding (Manual) ( See: Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Hydraulic Brake System Bleeding (Pressure)). 13. When the desired pedal height is achieved, press the brake pedal to inspect for firmness. 14. Lower the vehicle. 15. Remove the scan tool. 16. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 17. Inspect the brake fluid level. Refer to Master Cylinder Reservoir Filling (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). 18. Road test the vehicle while inspecting that the pedal remains high and firm. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed > Page 4116 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add GM approved brake fluid from a clean, sealed brake fluid container. Refer to Maintenance. See: Maintenance If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Maintenance. See: Maintenance 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed > Page 4117 Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed > Page 4118 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) Special Tools * CH-29532-A - Brake Pressure Bleeder, or equivalent * CH-35589-A - Brake Pressure Bleeder Adapter For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Note: The transmission must be in the PARK position, the power button in the OFF position, and the brakes not applied to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 1. Place the transmission in PARK. 2. Place the power button in the OFF position. 3. Remove the remote keyless entry (RKE) transmitter and close all of the vehicle doors. 4. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 5. With the power button OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 6. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 6.2-6.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 6.2-6.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 7. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 8. Install the CH-35589-A - Brake Pressure Bleeder Adapter to the brake master cylinder reservoir. 9. Check the brake fluid level in the CH-29532-A - Brake Pressure Bleeder, or equivalent. Add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 10. Connect the CH-29532-A - Brake Pressure Bleeder, or equivalent , to the CH-35589-A - Brake Pressure Bleeder Adapter. 11. Charge the CH-29532-A - Brake Pressure Bleeder, or equivalent , air tank to 175-205 kPa (25-30 psi). 12. Open the CH-29532-A - Brake Pressure Bleeder, or equivalent , fluid tank valve to allow pressurized brake fluid to enter the brake system. 13. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 14. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve. 16. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 17. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed > Page 4119 tighten the bleeder valve. 18. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 19. Install a transparent hose over the end of the bleeder valve, then repeat steps 16-17. 20. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 21. Install a transparent hose over the end of the bleeder valve, then repeat steps 16-17. 22. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 23. Install a transparent hose over the end of the bleeder valve, then repeat steps 16-17. 24. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 25. Close the CH-29532-A - Brake Pressure Bleeder, or equivalent , fluid tank valve, then disconnect the CH-29532-A - Brake Pressure Bleeder, or equivalent , from the CH-35589-A - Brake Pressure Bleeder Adapter. 26. Remove the CH-35589-A - Brake Pressure Bleeder Adapter from the brake master cylinder reservoir. 27. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 28. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 29. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to Antilock Brake System Automated Bleed (See: Antilock Brake System Automated Bleed). 30. Turn the power button ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 31. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed > Page 4120 Brake Bleeding: Service and Repair Hydraulic Brake System Flushing Hydraulic Brake System Flushing Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination: * Fluid separation, indicating two types of fluid are present; a substance other than the recommended brake fluid has been introduced into the brake hydraulic system: - Swirled appearance-oil-based substance - Layered appearance-silicone-based substance * Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system: - Cloudy appearance-moisture - Dark appearance/suspended particles in fluid-dirt, rust, corrosion, brake dust 2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination. 3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: 1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (Left Hand Drive) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement) * Front Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Front Brake Hose Replacement) * Rear Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement) * Front Brake Caliper Replacement (See: Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement) * Rear Brake Caliper Replacement (with Dampener) (See: Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (with Dampener)) * Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake Pressure Modulator Valve Replacement) * Hydraulic Brake System Bleeding (Manual) (See: Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Hydraulic Brake System Bleeding (Pressure)) 2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (Left Hand Drive) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement); also perform the following: * Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement (See: Brake Fluid Reservoir/Service and Repair). * Replace the brake master cylinder reservoir cap diaphragm. * Front Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Front Brake Hose Replacement) * Rear Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement) * Front Brake Caliper Overhaul (See: Brake Caliper/Service and Repair/Overhaul)or Front Brake Caliper Replacement (See: Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement) * Rear Brake Caliper Replacement (with Dampener) (See: Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (with Dampener)) 4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The diaphragm may have allowed the moisture or particles to enter the hydraulic system. 5. Fill the brake master cylinder reservoir to the maximum-fill level with GM recommended brake fluid. Refer to Adhesives, Fluids, Lubricants, and Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Automated Bleed > Page 4121 Sealers (See: Specifications) for the recommended brake fluid. 6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) (See: Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Hydraulic Brake System Bleeding (Pressure)). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Testing and Inspection Brake Caliper: Testing and Inspection Brake Caliper Inspection 1. Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage. If any of these conditions are present, the brake caliper requires replacement. 2. Inspect the caliper piston dust boot seal (6) for cracks, tears, cuts, deterioration and/or improper seating in the caliper body. If any of these conditions are present, the brake caliper requires overhaul or replacement. 3. Renew brake caliper bleeder valve cap (3) if missing. 4. Check for blocked bleeder valve (2). 5. Inspect for smooth and complete travel of the caliper pistons into the caliper bores: The movement of the caliper pistons into the caliper bores should be smooth and even. If the caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement. Insert a discarded inner brake pad (2) or block of wood in front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the piston in the bore. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement Brake Caliper: Removal and Replacement Front Brake Caliper Bracket Replacement (15 inch Brake System) Front Brake Caliper Bracket Replacement (15 inch Brake System) Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 6. Remove the lower brake caliper guide pin bolt (4). Do NOT disconnect the hydraulic brake flexible hose (1) from the caliper (2). Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 7. Without disconnecting the hydraulic brake flexible hose (1), pivot the caliper (2) upward and separate from caliper bracket in direction of arrow. 8. Remove the brake pads (3). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4127 9. Remove the brake pad retainer springs (1). 10. If reusing the bracket, thoroughly clean the pad hardware mating surfaces of the caliper bracket, of any debris and corrosion. 11. Inspect the brake pad retainer springs (1) for the following: * Bent mounting tabs * Excessive corrosion * Looseness at the brake caliper mounting bracket * Looseness at the disc brake pads 12. If any of the conditions listed are found, the disc brake pad retainers require replacement. 13. Remove and DISCARD caliper bracket bolts (2). 14. Remove brake caliper bracket (1) from steering knuckle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4128 15. Inspect the caliper bracket (5). If the brake caliper bracket (5) is bent, cracked, or damaged, it requires replacement. 16. Inspect the brake caliper guide pins (3) for freedom of movement, and inspect the condition of the guide pin boots (4). Move the brake caliper guide pins (3) inboard and outboard within the brake caliper bracket (5), without disengaging the slides from the boots (4), and observe for the following: * Restricted caliper guide pin movement * Looseness in the brake caliper mounting bracket * Seized or binding caliper guide pins * Split or torn boots 17. If any of the conditions listed are found, the brake caliper guide pins (3) and/or boots (4) require replacement. Installation Procedure 1. Install the brake caliper bracket (1) to the steering knuckle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the NEW brake caliper bracket bolts (2) and tighten to 100 Nm (74 lb ft) + 60° - 75° Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4129 3. Apply a very thin coating of high temperature silicone brake lubricant to the pad hardware mating surfaces of the caliper bracket only. 4. Install the brake pad retainer springs (1). Note: The wear sensor equipped disc brake pad must be mounted inboard of the rotor with the leading edge of the sensor facing the brake rotor during forward wheel rotation, or at the top of the pad when installed in vehicle position. 5. Install the brake pads (3) to the brake caliper bracket. 6. Remove the support and reposition the brake caliper (2) over the brake pads and to the caliper bracket. Assure that guide pin bolts boots apply firmly. 7. Install guide pin bolts and tighten to 28 Nm (21 lb ft). 8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads. 13. Fill the master cylinder auxiliary reservoir to the proper level. Refer to Master Cylinder Reservoir Filling (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4130 Front Brake Caliper Replacement Front Brake Caliper Replacement Removal Procedure Warning Use of eye goggles is necessary to prevent personal injury. Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 6. Remove the brake hose-to-caliper bolt (3) from the brake caliper. 7. Remove the brake hose (2) from the brake caliper. Remove and discard the copper brake hose washers. These washers may be stuck to the brake caliper and/or the brake hose end. 8. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination. 9. Remove the brake caliper guide pin bolts (1). 10. Remove the brake caliper from the caliper bracket. 11. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: * Restricted caliper guide pin movement * Looseness in the brake caliper mounting bracket * Seized or binding caliper guide pins * Split or torn boots 12. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4131 1. Install the brake caliper to the brake caliper bracket. Note: Do not reuse the brake hose washers. 2. Install NEW copper brake hose washers (1) to the brake hose-to-caliper bolt and to the brake hose. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 3. Install the brake caliper guide pin bolts (1) and tighten to 28 Nm (21 lb ft). 4. Remove the caps or plugs from the brake caliper opening and the brake hose. 5. Install the brake hose (2) to the caliper. 6. Install brake hose-to-caliper bolt (3) to the caliper and tighten to 40 Nm (30 lb ft). 7. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Pressure)). 8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4132 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 10 and 11 until a firm brake pedal is obtained. This will properly seat the brake caliper piston and brake pads. Front Brake Caliper Hardware Replacement Front Brake Caliper Hardware Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 6. Remove the brake caliper lower guide pin bolt (2). Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 7. Without disconnecting the hydraulic brake flexible hose, pivot the caliper (1) upward and secure the caliper with heavy mechanics wire, or equivalent. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4133 8. Remove the brake pads (1) from the caliper mounting bracket 9. Remove the brake pad retainer springs (1) from the caliper bracket. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4134 10. Remove the brake caliper guide pins (3) from the brake caliper mounting bracket (1). 11. Remove the brake caliper pin boots (2) from the brake caliper mounting bracket (1). Installation Procedure 1. Apply a thin coat of high temperature silicone lube to the brake caliper guide pin boots. 2. Install the brake caliper pin boots (2) into the brake caliper mounting bracket (1). Do not hammer the caliper pin boots into the bracket. Ensure that the caliper pin boots are fully seated in the bracket. 3. Apply a thin coat of high temperature silicone lube to the brake caliper guide pins. 4. Install the brake caliper guide pins (3) to the brake caliper mounting bracket (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4135 5. Ensure the brake pad hardware mating surfaces are clean. 6. Install the brake pad retainers (1) to the brake caliper bracket. Note: The wear sensor equipped disc brake pad must be mounted inboard of the rotor with the leading edge of the sensor facing the brake rotor during forward wheel rotation, or at the top of the pad when installed in vehicle position. 7. Install the brake pads (1) to the caliper bracket. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4136 8. Remove the support, and rotate the brake caliper (1) into position over the disc brake pads and to the caliper mounting bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the lower brake caliper guide pin bolts (2) and tighten to 28 Nm (21 lb ft). 10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 11. Lower the vehicle. 12. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance. 13. Slowly release the brake pedal. 14. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads. 15. Fill the master cylinder auxiliary reservoir to the proper level. Refer to Master Cylinder Reservoir Filling (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). Rear Brake Caliper Hardware Replacement Rear Brake Caliper Hardware Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4137 6. Remove the upper brake caliper pin bolt (1). 7. Remove the brake caliper vibration dampener (3). 8. Remove the brake pads (1) from the caliper mounting bracket (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4138 9. Remove the brake pad retainer springs (1) from the caliper bracket (2). 10. Remove the brake caliper guide pins (3) from the brake caliper mounting bracket (1). 11. Remove the brake caliper pin boots (2) from the brake caliper mounting bracket (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4139 1. Apply a thin coat of high temperature silicone lube to the brake caliper guide pin boots. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Disc Brake System/Specifications/Fluid Type Specifications) for the recommended lubricant. 2. Install the brake caliper pin boots (2) into the brake caliper mounting bracket (1). Do not hammer the caliper pin boots into the bracket. Ensure that the caliper pin boots are fully seated in the bracket. 3. Apply a thin coat of high temperature silicone lube to the brake caliper guide pins. 4. Install the brake caliper guide pins (3) to the brake caliper mounting bracket (1). 5. Ensure the brake pad hardware mating surfaces are clean. 6. Install the brake pad retainers (1) to the brake caliper bracket and apply a thin coat of high temperature silicone lube to the brake pad retainers. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4140 Note: The wear sensor equipped disc brake pad must be mounted inboard of the rotor with the leading edge of the sensor facing the brake rotor during forward wheel rotation, or at the top of the pad when installed in vehicle position. 7. Install the brake pads (1) to the caliper bracket. 8. Install the brake caliper (2) to the brake caliper bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the lower brake caliper pin bolt (1) and tighten to 28 Nm (20 lb ft). 10. Install the brake caliper vibration dampener (3) and tighten to 28 Nm (20 lb ft). Note: Position of brake caliper piston cavity MUST aligned horizontally to the embossed marking of brake caliper in order to prevent an appropriate installation. 11. Check position of piston cavity after assembling caliper. 12. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 13. Lower the vehicle. 14. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4141 15. Slowly release the brake pedal. 16. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads. 17. Fill the master cylinder auxiliary reservoir to the proper level. Refer to Master Cylinder Reservoir Filling (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). Rear Brake Caliper Bracket Replacement Rear Brake Caliper Bracket Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Note: Remove and discard the brake caliper pin bolts. 3. Remove the brake caliper from the brake caliper bracket (3) and support the brake caliper with heavy mechanic's wire, or equivalent. Do NOT disconnect the hydraulic brake flexible hose from the caliper. Refer to Rear Brake Caliper Replacement (with Dampener) (See: Rear Brake Caliper Replacement (with Dampener)). 4. Remove the brake pads from the brake caliper bracket (3). 5. Remove the brake pad retainers from the brake caliper bracket. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4142 Note: Discard the brake caliper bracket bolts. 6. Remove the brake caliper bracket bolts (1). 7. Remove the rear brake caliper bracket. 8. Inspect the brake mounting and hardware. Refer to Rear Brake Caliper Hardware Replacement (See: Rear Brake Caliper Hardware Replacement ). 9. Inspect the brake caliper bracket. 10. Replace the brake caliper bracket if cracked or damaged. Installation Procedure 1. Install the brake caliper bracket. Caution: This is a self-retaining fastener joint that does not require thread locking compounds. Do not attempt to clean the threads with a standard tap. If a standard tap is used, damage to the joint threads will occur. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the NEW brake caliper mounting bracket bolts (1) and tighten to 100 Nm (74 lb ft) + 60° 75°. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4143 3. Install the brake pad retainers (2) to the brake caliper bracket (3). 4. Install the brake pads (1) to the brake caliper bracket. 5. Install the brake caliper. Refer to Rear Brake Caliper Replacement (with Dampener) (See: Rear Brake Caliper Replacement (with Dampener)). 6. Install the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 7. Lower the vehicle. 8. Pump the brake pedal 2-3 times in order to seat the rear disc brake pads to the rotor. Rear Brake Caliper Replacement (with Dampener) Rear Brake Caliper Replacement (with Dampener) Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4144 6. Remove the brake hose to caliper bolt (2) from the brake caliper. 7. Remove the brake hose (1) from the brake caliper. 8. Remove and discard the 2 copper brake hose gaskets (3). These gaskets may be stuck to the brake caliper and/or the brake hose end. 9. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination. 10. Remove the upper brake caliper pin bolt (1). 11. Remove the brake caliper vibration dampener (3). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4145 12. Remove the park brake cable from the rear parking brake lever (1). 13. Remove the brake caliper from the brake caliper bracket. Installation Procedure 1. Inspect the caliper slide boots for cuts, tears, or deterioration. If damaged, replace the slides and boots. Refer to Rear Brake Caliper Hardware Replacement (See: Rear Brake Caliper Hardware Replacement). 2. Install the brake caliper to the brake caliper bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the lower brake caliper pin bolt (1) and tighten to 28 Nm (20 lb ft). 4. Install the brake caliper vibration dampener (3) and tighten to 28 Nm (20 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4146 5. Install the park brake cable to the rear parking brake lever (1). 6. Remove the caps or plugs from the brake caliper opening and the brake hose. Note: DO NOT reuse the copper brake hose gaskets. 7. Install NEW copper brake hose gaskets (3) to the brake hose-to-caliper bolt (2) and to the brake hose. 8. Install the brake hose and the brake hose-to-caliper bolt to the brake caliper and tighten the bolt to 40 Nm (30 lb ft). 9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Pressure)). 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 9 and 10 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 13. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 14. Lower the vehicle. 15. Apply and release the park brake lever 4 times. Rear Brake Caliper Vibration Dampener Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4147 Rear Brake Caliper Vibration Dampener Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Open the cap (2) of the brake caliper vibration damper (1), to gain access to the internal torx. 4. Remove the brake caliper vibration damper (2) from the brake caliper vibration damper stud (1). Hold against internal torx of damper stud (1). 5. Remove the damper stud (1) from the rear brake. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4148 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the damper stud (1) to the rear brake and tighten to 28 Nm (21 lb ft). 2. Attach the brake caliper vibration damper (2) to the stud (1) by turn in 2 threads ONLY. 3. Tighten the brake caliper vibration damper (2) to 9 Nm (80 lb in) with a suitable tool. 4. Close the cap (2) of the brake caliper vibration damper (1). 5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) 6. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4149 Brake Caliper: Overhaul Front Brake Caliper Overhaul Disassembly Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Warning Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury. Caution: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. 1. Remove the brake caliper from the vehicle. Refer to Front Brake Caliper Replacement (See: Removal and Replacement/Front Brake Caliper Replacement). 2. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the caliper (1) through the fluid inlet hole. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4150 3. Remove the piston dust boot seal (1) from the seal counterbore in the caliper (4). Discard the boot seal. 4. Using a small wooden or plastic tool, remove the piston seal (3) from the caliper bore. Discard the piston seal. 5. Remove the bleeder valve cap (6). 6. Remove the bleeder valve (5). Note: Do not use abrasives to clean the brake caliper piston. 7. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 8. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 9. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent. 10. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered, compressed air. 11. Inspect the caliper piston for cracks, scoring, and/or damage to the plating. Replace the caliper piston if any of these conditions exist. 12. Inspect the caliper mounting holes for cracks, scoring, pitting, rust and/or excessive corrosion. Replace the caliper assembly if any of these conditions exist. Assembly Procedure 1. Lubricate the new piston seal (3) with brake fluid from a clean, sealed brake fluid container. Refer to Adhesives, Fluids, Lubricants, and Sealers ( Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 4151 See: Disc Brake System/Specifications/Fluid Type Specifications) for the recommended brake fluid. 2. Install the lubricated, new piston seal (3) into the caliper bore. 3. Apply a thin coat of brake fluid from a clean, sealed brake fluid container. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Disc Brake System/Specifications/Fluid Type Specifications) for the recommended brake fluid. 4. Install the bottom half of the caliper piston (2) into the caliper bore. 5. Install the new piston dust boot seal (1) over the caliper piston (2). 6. Compress the caliper piston (2) to the bottom of the caliper bore. 7. Fully seat the piston dust boot seal (1) into caliper counterbore. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the bleeder valve to the caliper and tighten the valve to 17 Nm (13 lb ft). 9. Install the bleeder valve cap. 10. Install the brake caliper to the vehicle. Refer to Front Brake Caliper Replacement (See: Removal and Replacement/Front Brake Caliper Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Hydraulic Brake System: DOT 3 Hydraulic Brake Fluid (GM Part No. U.S. 88862806, in Canada 88862807). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Brake Fluid Level Sensor/Switch: Diagrams Component Connector End Views B20 Brake Fluid Level Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 4158 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Indicator Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Reservoir > Component Information > Service and Repair Brake Fluid Reservoir: Service and Repair Master Cylinder Reservoir Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Reservoir > Component Information > Service and Repair > Page 4162 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement Brake Hose/Line: Service and Repair Brake Pipe Replacement Brake Pipe Replacement Special Tools CH-45405 - Pipe Flaring Tool Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Warning Always use double walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and cause brake system failure. Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Note: When servicing the brake pipes, note the following: * If sectioning the brake pipe, use replacement pipe of the same type and outside diameter. * Use fittings of the appropriate size and type. * Only create flares of the same type or design as originally equipped on the vehicle. 1. Inspect the area of brake pipe to be repaired or replaced. 2. Release the brake pipe to be replaced from the retainers, as required. 3. Select an appropriate location to section the brake pipe, if necessary. * Allow adequate clearance in order to maneuver the CH-45405 - flaring tool. * Avoid sectioning the brake pipe at bends or mounting points. 4. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends. 5. Add to the measurement taken the appropriate additional length required for each flare to be created. * 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe * 9.50 mm (0.374 in) for 6.35 mm (1/4 in) diameter pipe Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 4167 * 12.67 mm (0.499 in) for 7.94 mm (5/16 in) diameter pipe Note: Ensure that the brake pipe end to be flared is cut at a square, 90 degree angle to the pipe length. 6. Using the pipe cutter included in the CH-45405 - flaring tool , carefully cut the brake pipe squarely to the measured length. 7. Remove the sectioned brake pipe from the vehicle. 8. Select the appropriate size of brake pipe and tube nuts, as necessary. The brake pipe outside diameter determines brake pipe size. 9. Strip the nylon coating from the brake pipe end to be flared, if necessary. * Select the appropriate blade on the coating stripping tool included in the CH-45405 - flaring tool , by unthreading the blade block from the stripping tool and installing the block with the desired blade facing the tool rollers. - 6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter pipe - 9.50 mm (0.374 in) blade for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe * Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool rollers. * While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel of the tool until the blade contacts the brake pipe coated surface. Note: Do not gouge the metal surface of the brake pipe. * Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains against the tool roller ledges. * After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe surface is exposed. * Loosen the thumbwheel of the tool and remove the brake pipe. Note: Ensure that all loose remnants of the nylon coating have been removed from the brake pipe. * Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been removed. - 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe - 9.50 mm (0.374 in) for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 4168 10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the CH-45405 - flaring tool. 11. Install the tube nuts on the brake pipe, noting their orientation. 12. Clean the brake pipe and the CH-45405 - flaring tool of lubricant, contaminants, and debris. 13. Loosen the die clamping screw of the CH-45405 - flaring tool. 14. Select the corresponding die set and install the die halves into the die cage with the full, flat face of one die facing the clamping screw, and the counterbores of both dies facing the forming ram. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 4169 15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold firmly against the counterbored face of the dies. 16. Insert the prepared end of the pipe to be flared through the back of the dies until the pipe is seated against the flat surface of the unused die (1). 17. Remove the unused die (1). 18. Ensure that the rear of both dies are seated firmly against the enclosed end of the die cage. 19. Firmly hand tighten the clamping screw (2) against the dies. 20. Select the appropriate forming mandrel and place into the forming ram. 21. Rotate the hydraulic fluid control valve clockwise to the closed position. 22. Rotate the body of the CH-45405 - flaring tool until it bottoms against the die cage. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 4170 23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever of the CH-45405 - flaring tool until the forming mandrel bottoms against the clamping dies. 24. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 25. Insert the finishing cone into the forming ram. 26. Rotate the hydraulic fluid control valve clockwise to the closed position. 27. Rotate the body of the CH-45405 - flaring tool until it bottoms against the die cage. 28. While guiding the finishing cone into the exposed end of pipe to be flared, operate the lever of the CH-45405 - flaring tool until the finishing cone bottoms against the dies. 29. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 30. Loosen the die clamping screw and remove the dies and pipe. 31. If necessary, lightly tap the dies until the die halves separate. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 4171 32. Inspect the brake pipe flare for correct shape and diameter (a). * 6.74-7.10 mm (0.265-0.279 in) flare diameter for 4.76 mm (3/16 in) diameter pipe * 8.57-9.27 mm (0.344-0.358 in) flare diameter for 6.35 mm (1/4 in) diameter pipe * 10.42-10.79 mm (0.410-0.425 in) flare diameter for 7.94 mm (5/16 in) diameter pipe 33. If necessary, using the removed section of brake pipe as a template, shape the new pipe with a suitable brake pipe bending tool. Note: When installing the pipe, maintain a clearance of 19 mm (3/4 in) from all moving or vibrating components. 34. Install the pipe to the vehicle with the appropriate brake pipe unions, as required. 35. If previously released, secure the brake pipe to the retainers. 36. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Pressure)). 37. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and applying the brakes. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 4172 Brake Hose/Line: Service and Repair Front Brake Hose Replacement Front Brake Hose Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Clean all dirt and foreign material from the brake hose ends and the brake pipe fitting. 4. Use a flare nut wrench on the brake pipe fitting (1) and a backup wrench on the brake hose (3) under the brake hose retainer (2) as shown. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 4173 5. Disconnect the brake pipe fitting (1) from the brake hose (3). Cap or plug the brake pipe fitting end and the brake hose end to prevent fluid loss and contamination. 6. Remove the brake hose retainer. 7. Remove the brake hose from the strut. 8. Remove the brake hose-to-caliper bolt from the brake caliper. 9. Remove the brake hose (3) from the brake caliper. 10. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end. 11. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination. Installation Procedure 1. Remove the caps or plugs from the opening in the brake caliper and the brake hose. Note: Install NEW copper brake hose gaskets. 2. Assemble the NEW copper brake hose gaskets and the brake hose bolt to the brake hose. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the brake hose-to-brake caliper bolt to the brake caliper and tighten the bolt to 40 Nm (30 lb ft). 4. Install the brake hose to the strut. 5. Remove the caps or plugs from the brake pipe fitting end and the brake hose end. 6. Install the brake hose to the brake hose body bracket. 7. Install the brake hose retainer (2) over the anti-rotation tabs of the brake hose (3). 8. Connect the brake pipe fitting (1) to the brake hose. 9. Use a backup wrench on the brake hose. 10. Tighten the brake pipe fitting to 18 Nm (14 lb ft). 11. Ensure that the hose does not make contact with any part of the suspension. Check the hose in extreme right and extreme left turn conditions. If the hose makes contact, remove the hose and correct the condition. 12. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Pressure)). 13. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 14. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 4174 Brake Hose/Line: Service and Repair Rear Brake Hose Replacement Rear Brake Hose Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove rear wheel speed sensor from brake hose. Refer to Rear Wheel Speed Sensor Replacement (Disc Brake) (See: Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Replacement (Disc Brake))Rear Wheel Speed Sensor Replacement (Drum Brake) (See: Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Replacement (Drum Brake)). 4. Clean all dirt and foreign material from the brake hose ends and the brake pipe fitting. 5. Use a flare nut wrench on the brake pipe fitting (1) and a backup wrench on the brake hose (3) under the brake hose retainer (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 4175 6. Disconnect the brake pipe fitting (1) from the brake hose (3). Cap or plug the brake pipe fitting end and the brake hose end to prevent fluid loss and contamination. 7. Remove the brake hose retainer (2). 8. Remove the brake hose bolt (2) attaching the hose to the rear brake caliper bracket. 9. Remove wiring harness (1) from brake hose bracket. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 4176 10. Remove the brake hose-to-caliper bolt (1) from the brake caliper (4). 11. Remove the brake hose (3) from the brake caliper. 12. Remove and discard the 2 copper brake hose gaskets (2). These gaskets may be stuck to the brake caliper and/or the brake hose end. 13. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination. Installation Procedure 1. Remove the caps or plugs from the opening in the brake caliper and the brake hose. Note: Install NEW copper brake hose gaskets. 2. Assemble the NEW copper brake hose gaskets (2), and the brake hose bolt (1), to the brake hose (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the brake hose-to-brake caliper bolt to the brake caliper (4) and tighten the bolt to 40 Nm (30 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 4177 4. Install the brake hose bolt (2) attaching the hose to the rear brake caliper bracket and tighten the bolt to 8 Nm (71 lb in). 5. Install wiring harness (1) at the brake hose bracket. 6. Remove the caps or plugs from the brake pipe fitting end and the brake hose end. 7. Install the brake hose to the brake hose body bracket. 8. Install the brake hose retainer (2) over the anti-rotation tabs of the brake hose (3). 9. Connect the brake pipe fitting (1) to the brake hose (3). 10. Use a backup wrench on the brake hose (3). 11. Tighten the brake pipe fitting to 18 Nm (13 lb ft). 12. Ensure that the hose does not make contact with any part of the suspension. Check the hose in extreme right and extreme left turn conditions. If the hose makes contact, remove the hose and correct the condition. 13. Install rear wheel speed sensor to brake hose. Refer to Rear Wheel Speed Sensor Replacement (Disc Brake) (See: Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Replacement (Disc Brake))Rear Wheel Speed Sensor Replacement (Drum Brake) (See: Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Replacement (Drum Brake)). 14. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Pressure)). 15. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 4178 16. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Testing and Inspection Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection Brake Pressure Modulator Valve Pressure Sensor Calibration The brake pressure sensor does not require calibration often. Calibration of the brake pressure sensor might be required after certain service procedures are performed. Some of these procedures are as follows: * Electronic brake control module (EBCM) replacement * Brake pressure modulator valve assembly replacement The Brake Pressure Sensor Calibration procedure can be completed with a scan tool using the following steps: 1. Apply the parking brake, or set the transmission in the P position. 2. Release the brake pedal. 3. Install the scan tool to the data link connector. 4. Ignition ON, engine OFF 5. Select Brake Pressure Sensor Calibration in the EBCM Configuration/Reset Functions list. 6. Follow the scan tool directions to complete the calibration procedure. 7. Clear any DTCs that may be set. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve Replacement Brake Pressure Modulator Valve Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Prepare electronic brake control module for replacement. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). 2. Turn the ignition to the OFF position. Note: Do NOT disconnect engine coolant hoses. 3. Remove the radiator surge tank clip (2). 4. Remove the radiator surge tank (1). Position the radiator surge tank (1) aside. Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. 5. Disconnect the electrical connector from the EBCM/EBTCM. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement > Page 4184 Note: Cap the brake pipe fittings to prevent brake fluid loss and contamination. 6. Remove the 6 brake pipes (1, 2) from the BPMV. 7. Remove the 2 BPMV bracket bolts (2). 8. Remove the BPMV bracket assembly (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement > Page 4185 9. Remove the 3 BPMV bracket bolts. 10. Remove the BPMV (2). 11. Remove the BPMV insulator (1) from the BPMV bracket (3). Installation Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Install the BPMV insulator (1) to the BPMV bracket (3). 2. Install the BPMV (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 3 BPMV bracket bolts (4) and tighten to 10 Nm(89 lb in). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement > Page 4186 4. Install the BPMV bracket assembly (1). 5. Install the 2 BPMV bracket bolts (2) and tighten to 20 Nm(15 lb ft). 6. Install the 6 brake pipes (1, 2) to the BPMV and tighten to 18 Nm(14 lb ft). 7. Connect the electrical connector to the EBCM/EBTCM. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement > Page 4187 8. Install the radiator surge tank (1). 9. Install the radiator surge tank clip (2). 10. Program the EBCM. Refer to Electronic Brake Control Module Programming and Setup (See: Testing and Inspection/Programming and Relearning/Electronic Brake Control Module Programming and Setup). 11. Perform the diagnostic system check - Vehicle. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). 12. Calibrate the brake pressure modulator valve pressure sensor. Refer to Brake Pressure Modulator Valve Pressure Sensor Calibration (See: Testing and Inspection). Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 13. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Pressure)). 14. Center the steering angle sensor. Refer to Steering Angle Sensor Centering (See: Sensors and Switches/Sensors and Switches - Steering and Suspension/Sensors and Switches - Steering/Steering Angle Sensor/Service and Repair/Procedures). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement > Page 4188 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve Bracket Replacement Brake Pressure Modulator Valve Bracket Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Turn the ignition to the OFF position. Note: Do NOT disconnect engine coolant hoses. 2. Remove the radiator surge tank clip (2). 3. Remove the radiator surge tank (1). Position the radiator surge tank (1) aside. Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. 4. Disconnect the electrical connector from the EBCM/EBTCM. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement > Page 4189 Note: Cap the brake pipe fittings to prevent brake fluid loss and contamination. 5. Remove the 6 brake pipes (1, 2) from the BPMV. 6. Remove the 2 BPMV bracket bolts (2). 7. Remove the BPMV bracket assembly (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement > Page 4190 8. Remove the 3 BPMV bracket bolts. 9. Remove the BPMV (2). 10. Remove the BPMV insulator (1) from the BPMV bracket (3). Installation Procedure 1. Install the BPMV insulator (1) to the BPMV bracket (3). 2. Install the BPMV (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 3 BPMV bracket bolts (4). Tighten the BPMV bracket bolts 10 Nm (89 lb in). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement > Page 4191 4. Install the BPMV bracket assembly (1). 5. Install the 2 BPMV bracket bolts (2) and tighten to 20 Nm (15 lb ft). 6. Install the 6 brake pipes (1, 2) to the BPMV and tighten to 18 Nm (14 lb ft). 7. Connect the electrical connector to the EBCM/EBTCM. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement > Page 4192 8. Install the radiator surge tank (1). 9. Install the radiator surge tank clip (2). 10. Program the EBCM. Refer to Electronic Brake Control Module Programming and Setup (See: Testing and Inspection/Programming and Relearning/Electronic Brake Control Module Programming and Setup). 11. Perform the diagnostic system check - Vehicle. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). 12. Calibrate the brake pressure modulator valve pressure sensor. Refer to Brake Pressure Modulator Valve Pressure Sensor Calibration (See: Testing and Inspection). Caution: When adding fluid to the brake master cylinder reservoir, use only GM approved or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 13. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Pressure)). 14. Center the steering angle sensor. Refer to Steering Angle Sensor Centering (See: Sensors and Switches/Sensors and Switches - Steering and Suspension/Sensors and Switches - Steering/Steering Angle Sensor/Service and Repair/Procedures). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures Brake Master Cylinder: Procedures Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir (1). 5. Fill the master cylinder reservoir to at least the half-way point with brake fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications) for the recommended brake fluid. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 in), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir (1). 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Master Cylinder Reservoir Filling Master Cylinder Reservoir Filling Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: When adding fluid to the brake master cylinder reservoir, use only GM approved or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4197 1. Visually inspect the brake fluid level through the brake master cylinder auxiliary reservoir. 2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system should be inspected for wear and possible brake fluid leaks. 3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the maximum-fill level. 4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill level. 5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal conditions. 6. If brake fluid is to be added to the master cylinder auxiliary reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4198 Brake Master Cylinder: Removal and Replacement Master Cylinder Replacement (Left Hand Drive) Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Disconnect the brake fluid level indicator switch electrical connector and separate from brake fluid reservoir. 2. Disconnect the master cylinder secondary brake pipe fitting (1). Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination. 3. Disconnect the master cylinder primary brake pipe fitting (1). Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4199 4. Remove and DISCARD master cylinder nuts (1). 5. Remove master cylinder with brake fluid reservoir. 6. Inspect the master cylinder to vacuum brake booster seal for damage and replace, if necessary. 7. Remove the master cylinder reservoir, if necessary. Refer to Master Cylinder Reservoir Replacement (See: Brake Fluid Reservoir/Service and Repair). Installation Procedure 1. Install the brake fluid reservoir to master cylinder. Refer to Master Cylinder Reservoir Replacement (See: Brake Fluid Reservoir/Service and Repair). 2. Ensure the master cylinder to vacuum brake booster seal is properly seated on the master cylinder barrel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install NEW master cylinder nuts (1) and tighten to 50 Nm (37 lb ft). 4. Install the brake fluid level indicator switch harness to the brake fluid reservoir and connect the electrical connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4200 5. Connect the master cylinder primary brake pipe fitting (1) and tighten to 18 Nm (13 lb ft). 6. Connect the master cylinder primary brake pipe fitting (1) and tighten to 18 Nm (13 lb ft). 7. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Pressure)). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair Wheel Cylinder: Service and Repair Rear Brake Cylinder Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the brake drum. Refer to Brake Drum Replacement (See: Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 4. Remove brake shoes. Refer to Brake Shoe Replacement (See: Drum Brake System/Brake Shoe/Service and Repair). 5. Clean any debris and contaminants from around the wheel cylinder. 6. Disconnect the brake pipe fitting (1) from the wheel cylinder. Cap the exposed brake pipe end to prevent fluid loss and 7. Remove the 2 wheel cylinder mounting bolts (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Page 4204 8. Remove the wheel cylinder (1) from the backing plate. Installation Procedure 1. Install the wheel cylinder (1) to backing plate. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Page 4205 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install wheel cylinder mounting bolts (2) and tighten to 10 Nm (89 lb in). 3. Connect the brake pipe fitting (1) at the wheel cylinder and tighten to 18 Nm (14 lb ft). 4. Install the brake shoes. Refer to Brake Shoe Replacement (See: Drum Brake System/Brake Shoe/Service and Repair). 5. Install the brake drum. Refer to Brake Drum Replacement (See: Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement ). 6. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Pressure)). 7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 8. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable Replacement (Conventional Parking Brake) Parking Brake Cable: Service and Repair Parking Brake Cable Replacement (Conventional Parking Brake) Parking Brake Cable Replacement (Conventional Parking Brake) Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Removal Procedure 1. Remove the front floor console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). 2. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement (See: Body and Frame/Seats/Seat Cushion/Service and Repair/Rear Seat Cushion Replacement). 3. Remove the front and rear side door sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement (See: Body and Frame/Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement) and Rear Side Door Sill Trim Plate Replacement (See: Body and Frame/Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement). 4. Partially remove the rear floor carpet (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable Replacement (Conventional Parking Brake) > Page 4211 5. Remove the parking brake cable (2) from the parking brake lever (1). 6. Remove the parking brake cable (2) from the parking brake cable bracket (3). 7. Remove the parking brake cable clip (1). 8. Remove the parking brake cable grommet (2). 9. Remove the parking brake cable casing retainer bolt (1). 10. Unclip the parking brake cable. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable Replacement (Conventional Parking Brake) > Page 4212 11. Remove the parking brake cable (1) from the rear brake caliper. Installation Procedure 1. Install the parking brake cable (1) to the rear brake caliper. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable Replacement (Conventional Parking Brake) > Page 4213 2. Clip in the parking brake cable (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the parking brake cable casing retainer bolt (1). Tighten the bolt 10 Nm (89 lb in). 4. Install the parking brake cable grommet (2). 5. Install the parking brake cable clip (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable Replacement (Conventional Parking Brake) > Page 4214 6. Install the parking brake cable (2) to the parking brake cable bracket (3). 7. Install in the parking brake cable (2) to the parking brake lever (1). 8. Install the rear floor carpet (1). 9. Install the front and rear side door sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement (See: Body and Frame/Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement) and Rear Side Door Sill Trim Plate Replacement (See: Body and Frame/Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement). 10. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement (See: Body and Frame/Seats/Seat Cushion/Service and Repair/Rear Seat Cushion Replacement). 11. Install the front floor console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable Replacement (Conventional Parking Brake) > Page 4215 Parking Brake Cable: Service and Repair Parking Brake Rear Cable Replacement Parking Brake Rear Cable Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Remove rear parking brake cable (1) from retainer (3). 4. Remove rear parking brake cable grommet (2) from rear backing plate. 5. Remove brake drum. Refer to Brake Drum Replacement (See: Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 6. Using a flat-bladed screwdriver, depress the visible retaining tab (1) on the park brake cable fitting, then tilt the released side of the cable end back into the backing plate. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable Replacement (Conventional Parking Brake) > Page 4216 7. Rotate the park brake cable to expose the other retaining tab. 8. Release rear parking brake cable (1) from parking brake lever (2), using a suitable tool. 9. Remove the rear parking brake cable (1) back through the opening in the backing plate. Installation Procedure 1. Insert the park brake cable through the opening in the backing plate. Only install the cable return spring to just rearward of the spring positioning tab on the backing plate. 2. Push the rear parking brake cable (1) toward the rear of the vehicle, along the outside of the trailing brake shoe, until the cable end is positioned just past the slot on the parking brake lever (2). 3. While holding the rear parking brake cable (1) in position from front to rear, move the cable end to the back of the parking brake lever (2). 4. Press the rear parking brake cable (1) into the slot on the lever (2), then pull the cable toward the front of the vehicle to secure the cable end to the slot. 5. While continuing to pull the cable away from the lever, insert a flat-bladed screwdriver into the opening on the lever to prevent the cable from lifting out of the slot on the lever. 6. Move the cable return spring through the opening in the backing plate. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable Replacement (Conventional Parking Brake) > Page 4217 7. Secure the cable fitting to the backing plate. Attempt to pull the park brake cable free of the backing plate, to ensure that the retaining tabs (1) on the fitting are properly secured. 8. Install rear parking brake cable (1) to retainer (3). 9. Install rear parking brake cable grommet (2) onto rear backing plate. 10. Install brake drum. Refer to Brake Drum Replacement (See: Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 11. Adjust the rear drum brakes. Refer to Drum Brake Adjustment (See: Drum Brake System/Adjustments). 12. Install the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) 13. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Replacement Parking Brake Lever: Service and Repair Parking Brake Lever Replacement Parking Brake Lever Replacement Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Removal Procedure 1. Remove the front floor console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). 2. Unhook the parking brake cable (1) from the parking brake lever (2). 3. Remove the parking brake indicator switch. Refer to Parking Brake Indicator Switch Replacement (See: Parking Brake Warning Switch/Service and Repair). 4. Remove the parking brake lever nut (1). 5. Remove the parking brake lever (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Replacement > Page 4222 Installation Procedure 1. Install the parking brake lever (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the parking brake lever nut (1). Tighten the nut to 10 Nm (89 lb in). 3. Install the parking brake indicator switch. Refer to Parking Brake Indicator Switch Replacement (See: Parking Brake Warning Switch/Service and Repair). 4. Hook in the parking brake cable (1) to the parking brake lever (2). 5. Remove the transit support (1). 6. Install the front floor console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Replacement > Page 4223 Parking Brake Lever: Service and Repair Parking Brake Lever Boot Replacement Parking Brake Lever Boot Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Locations Parking Brake Release Switch: Locations Instrument Panel/Center Console Component Views Center Console Components 1 of 5 1 - B80 Park Brake Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Locations > Page 4227 Parking Brake Release Switch: Diagrams Component Connector End Views B80 Park Brake Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Diagrams Brake Booster Vacuum Sensor: Diagrams Component Connector End Views B19C Brake Booster Vacuum Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair Hydraulic Brake Booster: Service and Repair Power Brake Booster Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Turn the ignition to the OFF position. Note: Do NOT disconnect engine coolant hoses. 2. Remove the radiator surge tank clip (2). 3. Remove the radiator surge tank (1). Position the radiator surge tank (1) aside. Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. 4. Disconnect the electrical connector from the EBCM/EBTCM. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Page 4238 Note: Cap the brake pipe fittings to prevent brake fluid loss and contamination. 5. Remove the 6 brake pipes (1, 2) from the BPMV. Note: Cap the brake pipe fittings to prevent brake fluid loss and contamination. 6. Disconnect the master cylinder secondary brake pipe fitting (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Page 4239 Note: Cap the brake pipe fittings to prevent brake fluid loss and contamination. 7. Disconnect the master cylinder primary brake pipe fitting (1). 8. Remove the BPMV bracket bolts (2). 9. Remove the BPMV bracket assembly (1). 10. Remove the brake master cylinder assembly from the booster. Refer to Master Cylinder Replacement (Left Hand Drive) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Page 4240 11. Remove the booster vacuum pipe (1) from the booster. 12. Disconnect the brake pedal pushrod (1) from the brake pedal. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Page 4241 13. Remove the brake booster bolts (1). 14. Remove the booster from the vehicle. Installation Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Install the booster to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the brake booster bolts (1) and tighten to 19 Nm (15 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Page 4242 3. Connect the brake pedal pushrod (1) to the brake pedal. 4. Install the booster vacuum pipe (1) to the booster. 5. Install the master cylinder assembly to the booster. Refer to Master Cylinder Replacement (Left Hand Drive) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Page 4243 6. Install the BPMV bracket assembly (1). 7. Install the BPMV bracket bolts (2) and tighten to 20 Nm (15 lb ft). 8. Connect the master cylinder primary brake pipe fitting (1) and tighten to 18 Nm (14 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Page 4244 9. Connect the master cylinder primary brake pipe fitting (1) and tighten to 18 Nm (14 lb ft). Note: Cap the brake pipe fittings to prevent brake fluid loss and contamination. 10. Install the 6 brake pipes (1, 2) to the BPMV and tighten to 18 Nm (14 lb ft). 11. Connect the electrical connector with to the EBCM/EBTCM. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Page 4245 12. Install the radiator surge tank (1). 13. Install the radiator surge tank clip (2). 14. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Pressure)). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster Pump > Component Information > Locations Hydraulic Brake Booster Pump: Locations Wheels/Vehicle Underbody Component Views Left Side Frame and Underbody Components 1 - M9 Brake Booster Pump Motor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster Pump > Component Information > Locations > Page 4249 Hydraulic Brake Booster Pump: Diagrams Component Connector End Views M9 Brake Booster Pump Motor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster Pump > Component Information > Locations > Page 4250 Hydraulic Brake Booster Pump: Service and Repair Power Brake Booster Pump Replacement Removal Procedure 1. Disconnect electrical connector (4). 2. Disconnect the vacuum hose quick fitting (1) from power brake booster vacuum pump (2). 3. Remove the bolts (3, 5). 4. Remove the power brake booster vacuum pump (2) with bracket from the vehicle. 5. Remove pump screws and nuts (1) from the power brake booster pump (2). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster Pump > Component Information > Locations > Page 4251 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 1. Install the pump screws and nuts (1) to the power brake booster pump (2) and tighten to 7.5 Nm (66 lb in). 2. Disconnect electrical connector (4). 3. Remove the power brake booster vacuum pump (2) with bracket from the vehicle. 4. Install the bolts (3, 5) and tighten to 20 Nm (15 lb ft). 5. Connect the vacuum hose quick fitting (1) to the power brake booster vacuum pump (2). 6. Connect the electrical connector (4). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Service and Repair > Power Brake Booster Vacuum Pipe Replacement (Left Hand Drive) Vacuum Pump: Service and Repair Power Brake Booster Vacuum Pipe Replacement (Left Hand Drive) Power Brake Booster Vacuum Pipe Replacement (Left Hand Drive) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Service and Repair > Power Brake Booster Vacuum Pipe Replacement (Left Hand Drive) > Page 4256 Vacuum Pump: Service and Repair Power Brake Booster Vacuum Pipe Replacement (Left Hand Drive with Electric Pump) Power Brake Booster Vacuum Pipe Replacement (Left Hand Drive with Electric Pump) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - K17 Electronic Brake Control Module (EBCM) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4261 Electronic Brake Control Module: Diagrams Component Connector End Views K17 Electronic Brake Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4262 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module Replacement (MK60 EC) Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement (MK60 EC) Electronic Brake Control Module Replacement (MK60 EC) Removal Procedure The electronic brake control module may not be replaced singly. Always replace control module in assemble with brake pressure modulator valve. Refer to Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly Antilock Brakes/Service and Repair/Brake Pressure Modulator Valve Replacement). Installation Procedure The electronic brake control module may not be replaced singly. Always replace control module in assemble with brake pressure modulator valve. Refer to Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly Antilock Brakes/Service and Repair/Brake Pressure Modulator Valve Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module Replacement (MK60 EC) > Page 4265 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement (MK60 P) Electronic Brake Control Module Replacement (MK60 P) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module Replacement (MK60 EC) > Page 4266 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Acceleration/Deceleration Sensor > Component Information > Locations Acceleration/Deceleration Sensor: Locations Instrument Panel/Center Console Component Views Center Console Components 2 of 5 1 - G307 Tunnel 2 - B119 Multi-axis Acceleration Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Acceleration/Deceleration Sensor > Component Information > Locations > Page 4271 Acceleration/Deceleration Sensor: Diagrams Component Connector End Views B119 Multi-Axis Acceleration Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Diagrams Brake Booster Vacuum Sensor: Diagrams Component Connector End Views B19C Brake Booster Vacuum Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Brake Fluid Level Sensor/Switch: Diagrams Component Connector End Views B20 Brake Fluid Level Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 4278 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Indicator Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations Parking Brake Release Switch: Locations Instrument Panel/Center Console Component Views Center Console Components 1 of 5 1 - B80 Park Brake Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Page 4282 Parking Brake Release Switch: Diagrams Component Connector End Views B80 Park Brake Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Passenger Compartment/Roof Component Views Wheel Speed Sensor: Locations Passenger Compartment/Roof Component Views Passenger Compartment/Roof Component Views Left Rear of the Passenger Compartment Components 1 of 2 1 - F105L Roof Rail Air Bag - Left 2 - B63LR Side Impact Sensor - Left Rear 3 - B5LR Wheel Speed Sensor - Left Rear 4 - G309 Panel Rear - Left 5 - G401 Panel Rear - Left Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Passenger Compartment/Roof Component Views > Page 4290 Wheel Speed Sensor: Locations Wheels/Vehicle Underbody Component Views Wheels/Vehicle Underbody Component Views Right Rear Frame and Underbody Components 1 - B5RR Wheel Speed Sensor - Right Rear Left Front Frame and Underbody Components 1 of 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Passenger Compartment/Roof Component Views > Page 4291 1 - B5LF Wheel Speed Sensor - Left Front Right Front Frame and Underbody Components Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Passenger Compartment/Roof Component Views > Page 4292 1 - B5RF Wheel Speed Sensor - Right Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 4293 Wheel Speed Sensor: Diagrams Component Connector End Views B5LF Wheel Speed Sensor - Left Front B5LR Wheel Speed Sensor - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 4294 B5RF Wheel Speed Sensor - Right Front B5RR Wheel Speed Sensor - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 4295 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement Front Wheel Speed Sensor Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the wheel speed sensor screw (2) from the steering knuckle. 4. Remove the wheel speed sensor (1). 5. Remove the wiring harness retainers from the frame. 6. Disconnect the electrical connector. 7. Remove wheel speed sensor (1) from the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 4298 Installation Procedure 1. Install the wheel speed sensor (1) to the vehicle. 2. Connect the electrical connector. 3. Install the wiring harness retainers to the frame. 4. Install the wheel speed sensor (1) to the steering knuckle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the wheel speed sensor screw (2) and tighten to 9 Nm (80 lb in). 6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 4299 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement (Disc Brake) Rear Wheel Speed Sensor Replacement (Disc Brake) Removal Procedure 1. Remove rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). 2. Remove the wheel speed sensor screw (2) from the steering knuckle. 3. Remove the wheel speed sensor (1). 4. Remove the wiring harness (3) from the bracket (4). 5. Remove the wiring harness (2) retainers (3) from the brake hose (4). 6. Remove the wiring harness (2) from the body retainer (1). 7. Replace the body retainer (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 4300 8. Disconnect the electrical connector (1). 9. Remove wheel speed sensor from the vehicle. Installation Procedure 1. Install the wheel speed sensor to the vehicle. 2. Connect the electrical connector (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 4301 3. Install the wiring harness (2) retainers (3) to the TOP SIDE of brake hose (4), using the marking points of old wiring harness. 4. Install the wiring harness (2) to the NEW body retainer (1). 5. Install the wheel speed sensor (1) to the steering knuckle. 6. Install the wiring harness (3) at the bracket (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the wheel speed sensor screw (2) and tighten to 6 Nm (53 lb in). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 4302 8. Check the correct installation position of the wiring harness (1). The wiring harness MUST be routed on top of the brake hose. If necessary adjust retainers (2) to the marking positions on the brake hose. 9. Apply tension to the wiring harness (1) between the retainers (2) for the correct routing. 10. Push down the brake hose by hand, to assure the correct installation position. 11. Install the rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 4303 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement (Drum Brake) Rear Wheel Speed Sensor Replacement (Drum Brake) Removal Procedure 1. Remove rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). 2. Remove the wheel speed sensor screw (2) from the steering knuckle. 3. Remove wheel speed sensor (1). 4. Remove wiring harness (3) from bracket (4). 5. Disconnect the electrical connector (1). 6. Remove wheel speed sensor from vehicle. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 4304 1. Install the wheel speed sensor to the vehicle. 2. Connect the electrical connector (1). 3. Install the wheel speed sensor (1) to steering knuckle. 4. Install wiring harness (3) at the bracket (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the wheel speed sensor screw (2) and tighten to 9 Nm (80 lb in). 6. Install rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Testing and Inspection Yaw Rate Sensor: Testing and Inspection Vehicle Yaw Sensor Learn The yaw sensor does not require calibration often. Calibration of the yaw rate sensor might be required after certain service procedures are performed. Some of these procedures are as follows: * Electronic brake control module (EBCM) replacement * Multi-axis acceleration sensor replacement The yaw rate sensor calibration procedure can be completed with a scan tool using the following steps: 1. Place vehicle on a level surface 2. Apply the parking brake, or set the transmission in the P position. 3. Install the scan tool to the data link connector. 4. Ignition ON, engine OFF. 5. Select Yaw Rate Sensor Reset in the Multi-axis Acceleration Sensor Module Configuration/Reset Functions list. 6. Follow the scan tool directions to complete the calibration procedure. 7. Select Yaw Rate Sensor Learn in the Multi-axis Acceleration Sensor Module Configuration/Reset Functions list. 8. Follow the scan tool directions to complete the calibration procedure. 9. Select Yaw Rate Sensor Learn in the EBCM Configuration/Reset Functions list. 10. Follow the scan tool directions to complete the calibration procedure. 11. Clear any DTCs that may be set. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Testing and Inspection > Page 4308 Yaw Rate Sensor: Service and Repair Vehicle Yaw Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Locations Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Side of the Engine Compartment Components 2 of 2 1 - B18 Battery Current Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Locations > Page 4314 Battery Current Sensor: Diagrams Component Connector End Views B18 Battery Current Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Locations > Page 4315 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Open the hood. 2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Remove the battery ground cable nut (1). 4. Remove the battery negative cable (2). 5. Disconnect the wiring harness current sensor plug (4). 6. Remove the current sensor (5) from the battery tray. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Locations > Page 4316 7. Remove the current sensor (2) from the battery negative cable (1). Installation Procedure 1. Install the current sensor (2) to the battery negative cable (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Locations > Page 4317 2. Install the current sensor (5) to the battery tray. 3. Connect the wiring harness current sensor plug (4). 4. Install the battery negative cable (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the battery ground cable nut (1) and tighten to 9 Nm (80 lb in). 6. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 7. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair Key and Lock Cylinder Coding Ignition Lock Cylinder The ignition lock cylinder uses 8 key cut positions, 1-8. The tumbler positions are staggered from side to side, four on one side and four on the other. Note: The tumblers (5) are not self-retaining and must be held in place if the key is not fully inserted into the lock cylinder or until the cylinder (2) is assembled into the case assembly (8). 1. Hold the cylinder assembly (2) so that the retainer pin pocket is facing upward. 2. Insert one tumbler spring (4) into each of the 4 spring wells. 3. The first tumbler (5) to be loaded will be the first key cut position, the first number in the key code. Install the first tumbler in the slot nearest the head of the lock cylinder. Install the remaining tumblers following the key code into the slots at the key cut positions 3, 5 and 7. It may be necessary to move the sidebar (already pre-assembled into the cylinder assembly) out slightly to fully install the tumbler into the correct slot. 4. Check the correct loading by holding the tumblers (5) in position and fully inserting the key into the cylinder assembly (2). All tumblers and the sidebar should be flushed with the outside diameter of the cylinder assembly body. 5. Rotate the cylinder assembly (2) so that the retention lug is facing upward and then remove the key, always holding all tumblers so they do not fall out. 6. Insert one tumbler spring (4) into each of the 4 spring wells. 7. The first tumbler (5) to be loaded will be the second key cut position, the second number in the key code. Install the tumbler in the slot nearest the head of the lock cylinder. Install the remaining tumblers following the key code into the slots at the key cut positions 4, 6 and 8. 8. Check for the correct loading by holding the tumblers (5) in position and fully inserting the key into the cylinder assembly (2). 9. Lightly lubricate the tumbler (5) surfaces and the small detent recess on the side of the cylinder assembly (2) using the lubrication provided. 10. With the key fully inserted, rotate the cylinder assembly so that the side with the retaining pin (7) pocket is facing upward. 11. Insert the retaining pin spring (6) and then retaining pin (7) into the pocket located behind the 4 tumblers. The retaining pin spring and retaining pin are not self-retaining and must be held in place until the cylinder is installed into the case assembly (8). 12. With the key fully inserted into the cylinder assembly and the retaining pin (7) fully depressed into the cylinder, align the retainer lug on the cylinder with the groove on the inside diameter of the case assembly (8). This groove extends the full length of the case assembly. 13. Install the cylinder assembly into the case assembly (8) being very careful to hold the retainer pin spring (6) and retainer pin (7) in the cylinder until they enter into the case assembly. With the cylinder fully inserted into the case assembly, rotate the cylinder counterclockwise until the retainer pin (7) snaps into place limiting the rotation of the cylinder assembly. 14. With the cylinder assembly in the Off-Lock position, insert the detent rod (1) into the hole in the side of the case assembly (8). Install the anti-rattle spring (3) into the case assembly over the detent spring. The anti-rattle spring should capture the detent ball and spring in the case assembly. Make sure both ends of the anti-rattle spring (3) are fully seated, pressed into, the case assembly. 15. With the cylinder assembly in the Off-Lock position, insert the detent rod (1) into the hole in the side of the case assembly (8). Install the anti-rattle spring (3) into the case assembly over the detent spring. The anti-rattle spring should capture the detent ball and spring in the case assembly. Make sure both ends of the anti-rattle spring (3) are fully seated, pressed into, the case assembly. Front Side Door Lock Cylinder Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Page 4322 1. Rotate the cylinder (8) so that the side with the tumbler spring wells faces up. 2. Insert the tumbler springs (4) into the 4 spring wells. 3. Install the tumbler (10) for key cut position 3 in the slot closest to the cylinder head. Install the remaining tumblers, key cut positions 5, 7 and 9, following the key code and same process. Press the tumblers in place until they are secure. 4. Check the correct loading of the tumblers by inserting the key into the cylinder. All tumblers should be flushed with the lock cylinder body. 5. Turn the cylinder so the side with the other tumbler spring wells faces up. 6. Insert the tumbler springs (4) into the 4 spring wells. 7. The first tumbler closest to the head of the lock cylinder to be loaded will be the fourth key cut position. Install the remaining tumblers for key cut positions 6, 8 and 10. Press the tumblers in place until they are secure. 8. Check the correct loading of the tumblers by inserting the key into the cylinder. All of the tumblers should be flushed with the lock cylinder body. 9. Apply lubricant to the cylinder body and tumbler surfaces along with a small amount in the head of the cylinder using the supplied lubricant. 10. Install the retainer (5) into the spring wells in the head of the lock cylinder. 11. Snap the shutter (7) into the cylinder. 12. Assemble the cylinder into the case (3). 13. Align dimples of the cylinder cap (6) with the 4 recesses in the cap. Secure by pressing the cap into place with light hand pressure. 14. Assemble the rod clip (2) to the lever (1). 15. Assemble the lever (1) to the lock. Use driver unit (11) to retain the lever assembly. 16. Assemble the gasket to the lock. 17. Insert the key into the lock and function the lock to check for proper assembly and smooth operation. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Neutral Safety Switch: Recalls Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 4331 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 4332 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Neutral Safety Switch: All Technical Service Bulletins Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 4338 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 4339 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4344 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4345 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4346 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Positive and Negative Cable Replacement (Gasoline) Negative: Service and Repair Battery Positive and Negative Cable Replacement (Gasoline) Battery Positive and Negative Cable Replacement (Gasoline) Removal Procedure 1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery Negative Cable Disconnection and Connection) 2. Unlock the retaining tabs on the battery fuse box cover, and open the cover (1). 3. Remove the battery positive cable to starter nut (2). 4. Remove the battery positive cable to starter (3) from the battery. 5. Remove the battery ground cable nut (1). 6. Remove the battery negative cable (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Positive and Negative Cable Replacement (Gasoline) > Page 4353 7. Remove the starter ground cable nut (2) from the starter motor (7). 8. Remove the negative cable (1). 9. Remove the starter and generator positive cable nut (5) and the starter positive cable nut (4). 10. Remove the 2 positive cables (3, 6). 11. Remove the rubber cap from the positive cable generator connector. 12. Remove the positive cable nut (1) from the generator (3). 13. Remove the generator positive cable (2) from the generator (3). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Positive and Negative Cable Replacement (Gasoline) > Page 4354 1. Install the positive cable (2) to the generator (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 2. Install the generator positive cable nut (1) to the generator (3) and tighten to 20 Nm (15 lb ft). 3. Install the rubber cap to the positive cable generator connector. 4. Install the 2 positive cables (3, 6). 5. Install the starter and generator positive cable nut (5) and the starter positive cable nut (4) and tighten to 12.5 Nm (111 lb in). 6. Install the negative cable (1). 7. Install the starter ground cable nut (2) to the starter motor (7) and tighten to 12.5 Nm (111 lb in). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Positive and Negative Cable Replacement (Gasoline) > Page 4355 8. Install the battery ground cable (2). 9. Install the battery negative cable nut (1) and tighten to 9 Nm (80 lb in). 10. Install the battery positive cable to starter (3) at the battery. 11. Install the battery positive cable to starter nut (2) and tighten to 12 Nm (106 lb in). 12. Close the cover (1) and lock the retaining tabs on the battery fuse box cover. 13. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery Negative Cable Disconnection and Connection) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Positive and Negative Cable Replacement (Gasoline) > Page 4356 Negative: Service and Repair Battery Negative Cable Replacement Battery Negative Cable Replacement Removal Procedure 1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery Negative Cable Disconnection and Connection). 2. Remove the battery ground cable nut (1). 3. Remove the battery negative cable (2). 4. Disconnect the wiring harness current sensor plug (4). 5. Remove the current sensor (5) from the battery tray. 6. Remove battery ground cable from the battery negative cable nut (2). 7. Remove the ground cable (3). 8. Remove the battery negative cable (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Positive and Negative Cable Replacement (Gasoline) > Page 4357 9. Remove the current sensor (2) from the battery negative cable (1). Installation Procedure 1. Install the current sensor (2) to the battery negative cable (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Positive and Negative Cable Replacement (Gasoline) > Page 4358 2. Install the battery negative cable (1). 3. Install the ground cable (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the battery ground cable to the battery negative cable nut (2) and tighten to 9 Nm (80 lb in). 5. Install the current sensor (5) at the battery tray. 6. Connect the wiring harness current sensor plug (4). 7. Install the battery negative cable (2). 8. Install the battery ground cable nut (1) and tighten to 9 Nm (80 lb in). 9. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery Negative Cable Disconnection and Connection). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Positive and Negative Cable Replacement (Gasoline) > Page 4359 Negative: Service and Repair Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection Removal Procedure 1. Turn on the radio and record all of the customer radio station presets. 2. Ensure that all lamps and accessories are turned off. 3. Turn the ignition OFF and remove the ignition key. Warning: Refer to Battery Disconnect Warning (See: Service Precautions). 4. Loosen the battery negative cable nut (2). 5. Remove the battery negative cable (1) from the battery. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Positive and Negative Cable Replacement (Gasoline) > Page 4360 1. Install the battery negative cable (1) to the battery. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Fasten the battery negative cable nut (2) and tighten the nut to 4.5 Nm (40 lb in). 3. Insert the ignition key and turn the ignition to the ON position. 4. Program volatile memory. Refer to Volatile Memory Programming (See: Testing and Inspection/Programming and Relearning/Volatile Memory Programming). 5. Program all of the customer's radio station presets and set the radio clock to the current time. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive and Negative Cable Replacement (Gasoline) Positive: Service and Repair Battery Positive and Negative Cable Replacement (Gasoline) Battery Positive and Negative Cable Replacement (Gasoline) Removal Procedure 1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Negative/Service and Repair/Battery Negative Cable Disconnection and Connection) 2. Unlock the retaining tabs on the battery fuse box cover, and open the cover (1). 3. Remove the battery positive cable to starter nut (2). 4. Remove the battery positive cable to starter (3) from the battery. 5. Remove the battery ground cable nut (1). 6. Remove the battery negative cable (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive and Negative Cable Replacement (Gasoline) > Page 4365 7. Remove the starter ground cable nut (2) from the starter motor (7). 8. Remove the negative cable (1). 9. Remove the starter and generator positive cable nut (5) and the starter positive cable nut (4). 10. Remove the 2 positive cables (3, 6). 11. Remove the rubber cap from the positive cable generator connector. 12. Remove the positive cable nut (1) from the generator (3). 13. Remove the generator positive cable (2) from the generator (3). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive and Negative Cable Replacement (Gasoline) > Page 4366 1. Install the positive cable (2) to the generator (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 2. Install the generator positive cable nut (1) to the generator (3) and tighten to 20 Nm (15 lb ft). 3. Install the rubber cap to the positive cable generator connector. 4. Install the 2 positive cables (3, 6). 5. Install the starter and generator positive cable nut (5) and the starter positive cable nut (4) and tighten to 12.5 Nm (111 lb in). 6. Install the negative cable (1). 7. Install the starter ground cable nut (2) to the starter motor (7) and tighten to 12.5 Nm (111 lb in). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive and Negative Cable Replacement (Gasoline) > Page 4367 8. Install the battery ground cable (2). 9. Install the battery negative cable nut (1) and tighten to 9 Nm (80 lb in). 10. Install the battery positive cable to starter (3) at the battery. 11. Install the battery positive cable to starter nut (2) and tighten to 12 Nm (106 lb in). 12. Close the cover (1) and lock the retaining tabs on the battery fuse box cover. 13. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Negative/Service and Repair/Battery Negative Cable Disconnection and Connection) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive and Negative Cable Replacement (Gasoline) > Page 4368 Positive: Service and Repair Battery Positive Cable Replacement Battery Positive Cable Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information > Locations Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Side of the Engine Compartment Components 2 of 2 1 - B18 Battery Current Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information > Locations > Page 4372 Battery Current Sensor: Diagrams Component Connector End Views B18 Battery Current Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information > Locations > Page 4373 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Open the hood. 2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Remove the battery ground cable nut (1). 4. Remove the battery negative cable (2). 5. Disconnect the wiring harness current sensor plug (4). 6. Remove the current sensor (5) from the battery tray. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information > Locations > Page 4374 7. Remove the current sensor (2) from the battery negative cable (1). Installation Procedure 1. Install the current sensor (2) to the battery negative cable (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information > Locations > Page 4375 2. Install the current sensor (5) to the battery tray. 3. Connect the wiring harness current sensor plug (4). 4. Install the battery negative cable (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the battery ground cable nut (1) and tighten to 9 Nm (80 lb in). 6. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 7. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Tray Replacement Battery Tray: Service and Repair Battery Tray Replacement Battery Tray Replacement Removal Procedure 1. Open the hood. 2. Remove the battery. Refer to Battery Replacement (See: Service and Repair/Removal and Replacement). 3. Unclip all wiring harness from the battery tray. 4. Unclip the engine control module bracket from the battery tray. 5. Unclip the radiator surge tank engine hose from the battery tray. 6. Remove the 3 battery tray bolts (1). 7. Remove the battery tray (2). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Tray Replacement > Page 4380 1. Install the battery tray (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 battery tray bolts (1) and tighten to 15 Nm (11 lb ft). 3. Clip in the radiator surge tank engine hose to the battery tray. 4. Install battery. Refer to Battery Replacement (See: Service and Repair/Removal and Replacement). 5. Clip in all wiring harness at the battery tray. 6. Clip in the engine control module bracket to the battery tray. 7. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Tray Replacement > Page 4381 Battery Tray: Service and Repair Battery Cover Replacement Battery Cover Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications Alternator: Specifications Generator Usage Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4386 Alternator: Diagrams Component Connector End Views G13 Generator X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4387 Alternator: Service and Repair Generator Replacement (1.4L LDD, LUH, and LUJ) Removal Procedure 1. Open the hood. 2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Disconnect the generator wiring harness connector (3). 5. Remove the generator positive cable nut (1). 6. Remove the generator positive cable (2). 7. Lower the vehicle. 8. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt Tensioner/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4388 9. Remove the 2 generator bolts (2). 10. Remove the generator (1) from above. Installation Procedure 1. Install the generator (1) from above. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 2 generator bolts (2) and tighten to 35 Nm (26 lb ft). 3. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt Tensioner/Service and Repair). 4. Raise and support the vehicle. 5. Connect the generator wiring harness connector (3). 6. Install the generator positive cable (2). 7. Install the generator positive cable nut (1) and tighten to 17 Nm (13 lb ft). 8. Lower the vehicle. 9. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery/Battery Cable/Negative/Service Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4389 and Repair/Battery Negative Cable Disconnection and Connection). 10. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Ignition Lock Solenoid > Component Information > Diagrams Ignition Lock Solenoid: Diagrams Component Connector End Views M932 Ignition Lock Cylinder Control Solenoid Actuator (MH8) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair Key and Lock Cylinder Coding Ignition Lock Cylinder The ignition lock cylinder uses 8 key cut positions, 1-8. The tumbler positions are staggered from side to side, four on one side and four on the other. Note: The tumblers (5) are not self-retaining and must be held in place if the key is not fully inserted into the lock cylinder or until the cylinder (2) is assembled into the case assembly (8). 1. Hold the cylinder assembly (2) so that the retainer pin pocket is facing upward. 2. Insert one tumbler spring (4) into each of the 4 spring wells. 3. The first tumbler (5) to be loaded will be the first key cut position, the first number in the key code. Install the first tumbler in the slot nearest the head of the lock cylinder. Install the remaining tumblers following the key code into the slots at the key cut positions 3, 5 and 7. It may be necessary to move the sidebar (already pre-assembled into the cylinder assembly) out slightly to fully install the tumbler into the correct slot. 4. Check the correct loading by holding the tumblers (5) in position and fully inserting the key into the cylinder assembly (2). All tumblers and the sidebar should be flushed with the outside diameter of the cylinder assembly body. 5. Rotate the cylinder assembly (2) so that the retention lug is facing upward and then remove the key, always holding all tumblers so they do not fall out. 6. Insert one tumbler spring (4) into each of the 4 spring wells. 7. The first tumbler (5) to be loaded will be the second key cut position, the second number in the key code. Install the tumbler in the slot nearest the head of the lock cylinder. Install the remaining tumblers following the key code into the slots at the key cut positions 4, 6 and 8. 8. Check for the correct loading by holding the tumblers (5) in position and fully inserting the key into the cylinder assembly (2). 9. Lightly lubricate the tumbler (5) surfaces and the small detent recess on the side of the cylinder assembly (2) using the lubrication provided. 10. With the key fully inserted, rotate the cylinder assembly so that the side with the retaining pin (7) pocket is facing upward. 11. Insert the retaining pin spring (6) and then retaining pin (7) into the pocket located behind the 4 tumblers. The retaining pin spring and retaining pin are not self-retaining and must be held in place until the cylinder is installed into the case assembly (8). 12. With the key fully inserted into the cylinder assembly and the retaining pin (7) fully depressed into the cylinder, align the retainer lug on the cylinder with the groove on the inside diameter of the case assembly (8). This groove extends the full length of the case assembly. 13. Install the cylinder assembly into the case assembly (8) being very careful to hold the retainer pin spring (6) and retainer pin (7) in the cylinder until they enter into the case assembly. With the cylinder fully inserted into the case assembly, rotate the cylinder counterclockwise until the retainer pin (7) snaps into place limiting the rotation of the cylinder assembly. 14. With the cylinder assembly in the Off-Lock position, insert the detent rod (1) into the hole in the side of the case assembly (8). Install the anti-rattle spring (3) into the case assembly over the detent spring. The anti-rattle spring should capture the detent ball and spring in the case assembly. Make sure both ends of the anti-rattle spring (3) are fully seated, pressed into, the case assembly. 15. With the cylinder assembly in the Off-Lock position, insert the detent rod (1) into the hole in the side of the case assembly (8). Install the anti-rattle spring (3) into the case assembly over the detent spring. The anti-rattle spring should capture the detent ball and spring in the case assembly. Make sure both ends of the anti-rattle spring (3) are fully seated, pressed into, the case assembly. Front Side Door Lock Cylinder Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Page 4399 1. Rotate the cylinder (8) so that the side with the tumbler spring wells faces up. 2. Insert the tumbler springs (4) into the 4 spring wells. 3. Install the tumbler (10) for key cut position 3 in the slot closest to the cylinder head. Install the remaining tumblers, key cut positions 5, 7 and 9, following the key code and same process. Press the tumblers in place until they are secure. 4. Check the correct loading of the tumblers by inserting the key into the cylinder. All tumblers should be flushed with the lock cylinder body. 5. Turn the cylinder so the side with the other tumbler spring wells faces up. 6. Insert the tumbler springs (4) into the 4 spring wells. 7. The first tumbler closest to the head of the lock cylinder to be loaded will be the fourth key cut position. Install the remaining tumblers for key cut positions 6, 8 and 10. Press the tumblers in place until they are secure. 8. Check the correct loading of the tumblers by inserting the key into the cylinder. All of the tumblers should be flushed with the lock cylinder body. 9. Apply lubricant to the cylinder body and tumbler surfaces along with a small amount in the head of the cylinder using the supplied lubricant. 10. Install the retainer (5) into the spring wells in the head of the lock cylinder. 11. Snap the shutter (7) into the cylinder. 12. Assemble the cylinder into the case (3). 13. Align dimples of the cylinder cap (6) with the 4 recesses in the cap. Secure by pressing the cap into place with light hand pressure. 14. Assemble the rod clip (2) to the lever (1). 15. Assemble the lever (1) to the lock. Use driver unit (11) to retain the lever assembly. 16. Assemble the gasket to the lock. 17. Insert the key into the lock and function the lock to check for proper assembly and smooth operation. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Interior/Locks - Key Cutting Procedure Key: Technical Service Bulletins Interior/Locks - Key Cutting Procedure INFORMATION Bulletin No.: 09-00-89-029F Date: January 05, 2011 Subject: Key Cutting Procedure for Obtaining Replacement Key Models: 2010-2011 Buick LaCrosse 2011 Buick Regal 2010-2011 Chevrolet Camaro, Equinox 2011 Chevrolet Cruze, Volt 2010-2011 GMC Terrain 2008-2009 Pontiac G8 Attention: This bulletin applies to the United States and Canada only. Export dealers are to contact their local Technical Assistance Center (TAC) for further information. Supercede: This bulletin is being revised to add the Chevrolet Volt. Please discard Corporate Bulletin Number 09-00-89-029E (Section 00 - General Information). Due to the uniqueness of the ignition/door lock key, special equipment is required to cut a key. If you do not have the required equipment, you may order a cut/coded key through GM CC&A.; To obtain a replacement key, the following procedure is suggested: 1. Obtain the vehicle key code. U.S. Dealers: Access the "Key Code Look Up" application through GM GlobalConnect under the Parts Workbench. Canadian Dealers: Access the "KeyCode Look-Up" feature within the OEConnection D2DLink application. 2. Submit a part order through the GM CC&A; Parts System for a key blank. Be sure to include the key code in the "note" field of the order. 3. DO NOT ORDER AN UNCODED KEY AS YOU WILL RECEIVE A BLANK KEY THAT WILL REQUIRE CODING ON THE SPECIAL EQUIPMENT LISTED BELOW. Note The key code is five digits. Some vehicle records do not have the first digit displayed (i.e., vehicle records show the key code as "1234"). When ordering a cut/coded key, refer to the key code table. Important The order will be shipped the same day if received by 12:00 p.m. (noon) EST, or within 24 hours, Monday through Friday via FedEx (Canadian dealers should place their orders for these parts using a CSO order type only. Do not order using the CSO3 order type). Important The remote control transmitter and the key shank are not serviced separately. Important Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Interior/Locks - Key Cutting Procedure > Page 4404 If a key is received with an incorrect cut contact the SPAC department for assistance. Tip The new key and transmitter will need to be programmed to the vehicle. Refer to Key and Transmitter Programming in SI for details. Parts Information For part numbers and usage, refer to Key in Group 02.187 of the appropriate parts catalog. Important As an alternate to Step 2, the following equipment can be purchased through 1-800-GM-TOOLS or by visiting www.GMDEsolutions.com (U.S.) or www.des-canada.ca (Canada). General Motors highly recommends the use of the following key machines. General Motors has identified superior equipment through testing and evaluation. General Motors believes these sources and their equipment to be reliable. There may be additional manufacturers of such equipment. General Motors does not endorse, indicate any preference for or assume any responsibility for the equipment from these firms or for any such items which may be available for other sources. Equipment Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Neutral Safety Switch: Recalls Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 4413 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 4414 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 10317 > Oct > 10 > Campaign Brake Apply Sensor Replacement Neutral Safety Switch: All Technical Service Bulletins Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 10317 > Oct > 10 > Campaign Brake Apply Sensor Replacement > Page 4420 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 10317 > Oct > 10 > Campaign Brake Apply Sensor Replacement > Page 4421 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations Starter Motor: Locations Powertrain Component Views Engine Components - Right Rear (LUJ) 1 - Q12 Evaporative Emission (EVAP) Purge Solenoid Valve 2 - Q17D Fuel Injector 4 3 - B74 Manifold Absolute Pressure Sensor 4 - Q17C Fuel Injector 3 5 - Q17B Fuel Injector 2 6 - Q17A Fuel Injector 1 7 - Q42 Turbocharger Wastegate Solenoid Valve 8 - B23F Camshaft Position Sensor - Intake 9 - Q6F Camshaft Position Actuator Solenoid Valve - Intake 10 - G13 Generator 11 - B52B Heated Oxygen Sensor 2 12 - B26 Crankshaft Position (CKP) Sensor 13 - M64 Starter Motor 14 - B17 Barometric Pressure (BARO) Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 4425 Starter Motor: Service and Repair Starter Replacement (1.4L LDD, LUH, and LUJ) Removal Procedure 1. Open the hood. 2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Remove the starter and generator positive cable nut (2). 5. Remove the starter and generator positive cable (1). 6. Remove the starter positive cable nut (3). 7. Remove the starter positive cable (4) from the starter. 8. Remove the starter ground cable nut (5). 9. Remove the ground cable (6). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 4426 10. Remove the upper starter bolt (2) and the washer (1). 11. Remove the starter bolt stud (4) and the washer (5). 12. Remove the starter (3). Installation Procedure 1. Install the starter (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the washer (5) and the starter bolt stud (4) and tighten to 25 Nm (18 lb ft). 3. Install the upper starter bolt (2) and the washer (1) and tighten to 25 Nm (18 lb ft). 4. Install the ground cable (6). 5. Install the starter ground cable nut (5) and tighten to 12.5 Nm (111 lb in). 6. Install the starter positive cable (4) to starter. 7. Install the starter positive cable nut (3) and tighten. 8. Install the starter and generator positive cable (1). 9. Remove the starter and generator positive cable nut (2) and tighten to 12.5 Nm (111 lb in). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 4427 10. Lower the vehicle. 11. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 12. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4431 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4432 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4433 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Accessory Relay > Component Information > Locations Accessory Relay: Locations Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Accessory Relay > Component Information > Locations > Page 4438 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4443 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4444 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4445 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4446 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4447 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4448 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4449 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4450 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4451 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4452 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4453 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4454 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4455 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4456 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4457 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4458 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4459 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4460 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4461 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4462 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4463 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4464 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4465 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4466 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4467 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4468 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4469 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4470 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4471 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4472 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4473 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4474 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4475 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4476 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4477 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4478 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4479 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4480 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4481 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4482 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4483 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4484 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4485 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4486 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4487 Auxiliary Power Outlet: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4488 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4489 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4490 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools EL-35616-200 - Test Light - Probe Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A Digital Multimeter (DMM) should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The EL-35616-200 - kit is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4491 Testing for a Short to Voltage Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J-25070 - Heat Gun For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, to move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to the Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J-25070 - heat gun. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4492 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. In addition, circuit cooling spray can be used to cool down a component or circuit. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4493 For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Special Tools Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4494 EL-35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4495 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Using Snapshots in Global Diagnostic System (GDS) Overview Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4496 A snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. To record a snapshot in GDS, select, Record Snapshot, from the options at the top right portion of any of the various pages that allow snapshots to be taken (e.g. Data Display, Control Functions, etc.). When you are finished recording, select, Stop Snapshot recording. The snapshot will now be available for replay. Snapshot Replay The Snapshot Replay function allows reviews of previously recorded vehicle snapshot data. This information can be used in analysis of vehicle problems and detection of trigger error conditions. The graph function can be used to compare parameters to see if a component is functioning properly. Recorded snapshots can be selected for viewing by the following three methods: * Selecting a snapshot file from the Vehicle Home Page and clicking on the Review selection. * Double clicking on the selected snapshot from the Vehicle Home Page. * Entering the Tools selection from the Menu selection and selecting Snapshot replay. Next, open the Snapshot Manager. Double click on the snapshot file you wish to view or click on the Load Snapshot selection and select a snapshot file. Regardless of selection method, a File Loaded pop-up window will be displayed from the Snapshot Replay screen. Select OK from the pop-up window. Snapshot Play Functions There are several snapshot play functions that are used to replay recorded snapshots * The Play function is used to play the snapshot forward by clicking on this selection. A marker will move across the screen when this selection is used. All selections in this area turn grey when they are active. * The Pause function is used to pause play of the snapshot. When this selection is clicked a second time the snapshot will start playing where it left off. * The Stop function is used to stop playing the snapshot. The snapshot will start from the beginning, if Play is selected after using the Stop function. Time Control Time control is used to control the snapshot replay. This function allows selection of a specific time frame, display of different views, and control of display speed. The following functions can be selected directly under Time Control. * The Bookmark selection allows you to add a specific comment in the current display and return to this point in the future. When this option is selected, a pop-up window is displayed. Enter a bookmark name and select OK. * The Note Pad can be selected to add comments to the snapshot replay file at the current point of time. When this option is selected, a pop-up window is displayed. Enter a comment for the snapshot file and select OK. * The Load Snapshot (blue folder) opens a snapshot file and makes it ready for further analysis. This function is also available by clicking on an available snapshot file from the Snapshot Manager. * The Down Arrow displays all Time Control options when selected. Individual options can also be selected by clicking on the item you want. * The Snapshot Display Speed can be controlled by selecting this option. Slow speeds of 1/8X, 1/4X, and 1/2X can be selected. The real time speed can also be selected at 1. Faster speeds of 2X, 4X, and 8X can also be obtained by using this selection. View Selections Each View Selection provides a different way of displaying vehicle data for analysis. The following functions can be selected under Available Views: Note: The parameter name will be shown in the original language used for capture if no translation is available for the name. * Parameter List View - Displays incoming information from the snapshot file. The current value of the parameters is displayed on the screen. * Log View - Contains all the information from the snapshot file. All parameter values are listed in the order they were recorded. Specific parameters can be added or removed from a watchlist by clicking on the appropriate item. * State View - Shows the values of all parameters in a specific time frame. These values can be used for comparison with the trigger view. * Trigger View - Displays all system and user defined triggers. This function can be used when there is a combination of factors involved in a diagnostic problem. When a Trigger condition is met a caution triangle will be displayed on the screen. Triggers: * Load Triggers - Allows you to load a file containing trigger definitions. * Save Triggers - Allows you to save the trigger to your computer's hard drive. * Remove Trigger - Allows you to remove the current trigger. It will no longer be present. * Edit Trigger - Displays a pop-up window where you can modify the limits and parameters contained within a trigger. * Adds Trigger - Displays a pop-up window to configure a trigger. * DTC View - After the Play function is selected and this option is selected this function opens the list of recorded DTCs. * Line Graph View - Displays data that can be visualized against the time-axis. From this view, specific parameters can be selected for graphing by Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4497 checking the box under Selected. At the bottom of the graph there are four functions Zoom In (increase size), Zoom Out (decrease size), Bookmarks, and Pause Scrolling. Each of these functions can be accessed by clicking on them. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools EL-39200 - Digital Multimeter For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the EL-39200 - digital multimeter (DMM). This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. Note: The DMM must be used in order to perform the following procedure since the DMM can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4498 Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the DMM to the circuit. 2. Set the DMM to the V (AC) or V (DC) position. 3. Select the voltage range feature of the DMM in order to select the desired voltage range. Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 4. Select the MIN MAX function of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button until the MAX value is displayed and note the value. 8. Press the MIN MAX button until the MIN value is displayed and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools EL-35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4499 To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the EL-35616 - kit when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center. Use EL-35616 - kit to test for proper terminal contact. Failure to use EL-35616 - kit can result in improper diagnosis of the bussed electrical center. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal/terminated lead, verify that the retention force is significantly different between a known good terminal and the suspect terminal. Replace the female terminal in question. Flat Wire Connectors There are no serviceable parts for flat wire connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter into the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Ground Distribution Schematics). Temperature Sensitivity Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4500 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures - In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference or other types of electrical noise. Inspect for the following conditions: * A mis-routed harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc.-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc.-These accessories may create interference in other circuits while operating and the interference would disappear when the accessory is not operating. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4501 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, current, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 Mohm input impedance 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Current 1. Test a DC current range of 0.1 µA-10 A. 2. Test an AC current range of 0.1 µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 Mohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 Hz-199 k Hz Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4502 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 25 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the engine control module (ECM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the EL-39200. The DMM instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Special Tools EL 35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools EL 35616-20F - Fused Jumper Wire For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: A fused jumper may not protect solid state components from being damaged. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4503 The EL 35616-20F - Fused Jumper Wire includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool * J-38125-216 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4504 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4505 3. Slide the lever lock forward while pressing down on the lever lock release tab. 4. View showing depressing of the lever lock release tab. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4506 5. View of connector in released position. 6. Disconnect the connector from the component. 7. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 8. Release the rear lower half of the wiredress cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4507 9. Release the tabs that are holding the wiredress cover to the connector body. 10. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J-38125-216 can also be used to remove the nose piece. 11. Use the J-38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4508 12. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 13. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 14. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-561 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4509 4. Insert the J-38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-213 - Terminal Release Tool * J-38125-556 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4510 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4511 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4512 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J-38125-213 or the J-38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. 10. Reconnect the connector bodies. Bosch Connectors (0.64) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4513 Bosch Connectors (0.64) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4514 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4515 11. Insert the J-38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 13. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 14. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4516 Bosch Connectors (2.8 JPT) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-557 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J-38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4517 * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT) )Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock))FCI Connectors (SIR) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI (SIR)) * FEP Connectors (Steering Gear) (See: General Electrical Diagnostic Procedures/Connector Repairs/FEP Connectors (Steering Gear)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) Connector Anatomy Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4518 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4519 * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4520 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4521 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4522 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4523 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools EL-38125-580 - Terminal Release Tool Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4524 Terminal Removal Procedure Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull to Seat) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4525 Delphi Connectors (Pull To Seat) Special Tools EL-38125-580 - Terminal Release Tool Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Review the connector end view to determine the proper test probe and release tool. 5. Insert the release tool into the front of the connector body. 6. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 3. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-21 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4526 Terminal Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4527 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4528 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wire dress cover and pull the lever over and past the locks. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4529 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4530 Note: Be careful not to angle or rock the J-38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J-38125-21 tool into the round canal between the terminals cavities at the front of the connector. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4531 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4532 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4533 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4534 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J-38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4535 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-10A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J-38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4536 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (12-Way) Delphi Connectors (12-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4537 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4538 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4539 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J-38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4540 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (Steering Gear) Delphi Connectors (Steering Gear) Removal Procedure 1. Use a small flat-bladed tool to release the locking tab on the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4541 2. Push down the locking tab to release the connector. The small flat-bladed tool may need to be pushed down and angled back slightly to depress the locking tab. Pull on the connector body while releasing the locking tab to disconnect the connector. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-556 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4542 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4543 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. 7. For the larger terminals insert the J-38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J-38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4544 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 9. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 10. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. FCI (SIR) FCI Connectors (SIR) Removal Procedure Note: The orange connector position assurance (CPA) must be released first to disconnect or to connect the connector. 1. Lift the orange CPA vertically (avoid lifting on an angle to the connector) approximately 4 mm to release the connector. Use a small flat-bladed Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4545 tool to help release the orange CPA. The orange CPA can also be released manually without any tools. 2. Grab the connector on both sides and lift the connector vertically to disconnect the connector. Installation Procedure 1. Lift the orange CPA vertically approximately 4 mm before installing the connector. Use a small flat-bladed tool to help release the orange CPA. The orange CPA can also be released manually without any tools. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4546 2. Line up the connector key tabs with the initiator key slots. Grab the connector on both sides and push the connector down into the initiator connector sub assembly until fully seated. 3. After the connector is fully seated, push down the orange CPA with your thumb. Push down until the orange CPA is touching the yellow cover on the connector. FEP Connectors (Steering Gear) FEP Connectors (Steering Gear) Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4547 1. Use a small flat-bladed tool to release the locking tab on the connector. 2. Push down the locking tab to release the connector. The small flat-bladed tool may need to be pushed down and angled back slightly to depress the locking tab. Pull on the connector body while releasing the locking tab to disconnect the connector. JST Connectors JST Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4548 The JST connector family consists of seven unique connector housings differentiated by color and keying. This connector family is designed to use both 0.64 and 2.8 sized terminals. 1. While depressing the lock, remove the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4549 2. Unlock the terminal position assurance (TPA): * Position connector as shown (above) and locate TPA staging cavities. * Using connector terminal release tool J-38125-553 (1) lift the TPA into the staged position (figure 1). Perform this step on both sides of the TPA. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4550 * You will feel the TPA click into place when fully extended into the staged position. The figure above shows the TPA (1) in the staged position. 3. Release the terminal from the connector: * Position the connector as shown (above) and locate the terminal release entry canal (1) of the suspect terminal. * Insert the connector terminal release tool J-38125-553 into the entry canal with the angled side of the tool facing the connector wall containing cavity 4 (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4551 * The cavity on the left (1) is a 2.8 mm cavity and the cavity on the right (2) is a 0.64 mm cavity. * Place the tip of the connector terminal release tool onto the connector lance (3) and deflect the lance to the right (5) to release the lock. Hold this released position. * Holding the lance in the released position, slightly pull on the suspect terminal to remove it from the connector housing. The side TPA (4) is a secondary lock. 4. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 5. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-24 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4552 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4553 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4554 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4555 8. Use the J-38125-24 or the J-38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-28 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4556 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4557 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J-38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4558 locked in place by gently pulling on the wire. 3. Locate the TPA. 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4559 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-213 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4560 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4561 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4562 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J-38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4563 Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4564 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J-38125-12A - tool into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4565 7. Pressing the J-38125-12A - tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool * J-38125-13A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-bladed tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4566 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-bladed tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J-38125-13A - tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J-38125-12A - tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4567 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4568 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4569 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4570 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4571 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4572 6. Use the J-38125-12A tool to release the terminals by pressing on the tang. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool * J-38125-212 - Terminal Release Tool * J-38125-216 - Terminal Release Tool * J-38125-221 - Terminal Release Tool * J-38125-560 - Terminal Release Tool * J-38125-566 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4573 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4574 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4575 Note: During assembly the terminal position assurance (TPA) will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J-38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4576 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4577 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4578 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J-38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4579 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4580 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4581 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4582 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4583 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. 22. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 23. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool * J-38125-212 - Terminal Release Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4584 * J-38125-556 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4585 Note: Terminal position assurance (TPA) is keyed and can only be inserted in one direction. 3. Using terminal release tool J-38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4586 5. Using terminal release tool J-38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4587 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4588 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4589 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4590 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4591 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4592 * J-38125-552 - Terminal Release Tool * J-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4593 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4594 5. Once the nose piece retainers are relaxed, use the J-38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4595 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4596 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4597 2. Insert the J-38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4598 5. Insert the J-38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-24 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4599 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4600 5. While pushing the terminal forward, insert the J-38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4601 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J-38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4602 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-215 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4603 1. While depressing the lock, pull the two connector halves apart. Note: The terminal position assurance (TPA) is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the TPA towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4604 4. View of the female half of the connector with male terminals. 5. Use the J-38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. 6. View of the female half of the connector with male terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4605 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 9. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 10. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Repairing Connector Terminals (Terminated Lead Repair) Repairing Connector Terminals (Terminated Lead Repair) Special Tools * EL-38125-10 - Splice Sleeve Crimp Tool * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs procedures. For high temperature wiring repairs, refer to High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs). Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to in Splicing Copper Wire Using Splice Sleeves to identify the correct DuraSeal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Repairing Connector Terminals (Terminal Repair) Repairing Connector Terminals (Terminal Repair) Special Tools * J-38125 - Terminal Repair Kit * J-38125-6 - Crimp Tool * J-38125-7 - Crimp Tool * J-38125-8 - Crimp Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4606 * J-38125-64 - Crimp Tool * J-38125-101 - Crimp Tool * J-38125-641 - Crimp Tool * J-38125-642 - Crimp Tool * J-38125-643 - Crimp Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Use the following repair procedures to repair each type of terminal: * For push to seat terminals, refer to Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)). * For pull to seat terminals, refer to Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)). Note: The first step for all terminal repairs is to find the connector end view in SI. Cable Seal Terminals 1. Cut off the terminal between the core and the insulation crimp to minimize any wire loss. 2. Remove the old seal. 3. Apply the correct cable seal, per the wire gauge size, from the kit. Slide the seal back along the wire to enable removal of the insulation. 4. To minimize wire loss, remove only the insulation required. 5. Using the connector end view, determine the correct crimp tool and crimp jaw. 6. Align the seal with the end of the cable insulation. 7. Position the stripped wire and seal in the terminal. 8. Hand Crimp the core wings first. 9. Hand Crimp the insulation wings around the seal and the cable. 10. Solder all of the hand crimp terminals except the Micro-Pack 100 and 0.64 sizes. Unsealed Terminals 1. Cut off the terminal between the core and the insulation crimp to minimize any wire loss. 2. To minimize wire loss, remove only the insulation required. 3. Position the stripped wire in the terminal. 4. Hand Crimp the core wings first. 5. Hand Crimp the insulation wings around the cable. 6. Solder all of the hand crimp terminals except the Micro-Pack 100 and 0.64 sizes. Micro-Pack 100W Size Terminal The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4607 the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Micro 0.64 Size Terminal The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J-38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J-38125-64 crimping tool is also designed to crimp Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4608 both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4609 7. Place the terminal into the appropriate cavity and assemble the connector. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4610 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch Special Tool * DuraSeal splice sleeves * A wire stripping tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4611 For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A terminated lead can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs in the service information connector end views or the vehicle schematics in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and EL-38125-10 - tool. For wiring repair, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. High Temperature Wiring Repairs High Temperature Wiring Repairs Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4612 Note: All wiring repairs need to be 200 mm from the heat zone. Areas of consideration would be any area located near the exhaust manifolds, catalytic converter, exhaust pipes, and turbocharged engines. Items Required * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * Terminated leads or pigtails * The correct tools to remove the terminals from the connectors Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing. * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Note: High temperature areas would be areas located near exhaust manifolds, catalytic converters, exhaust pipes, and turbocharged engines. Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4613 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. Terminated leads can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs in the service information connector end views or the vehicle schematics in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4614 the DuraSeal splice sleeves and EL-38125-10 - tool. For wiring repair, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). For connector position assurance (CPA), refer to Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks). For terminal position assurance (TPA), refer to Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks). Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except Tefzel and coaxial. Use DuraSeal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert to regional wiring gauge size. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. For high temperature wiring, slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4615 tubing will not interfere with the splice procedure. 5. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 6. Use the splice sleeve crimp tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 7. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 8. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 9. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4, 6 and 15 for the opposite end of the splice. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4616 10. Using the heat torch, apply heat to the crimped area of the barrel. 11. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. High Temperature Wiring Repairs Use the following procedures to perform high temperature wiring repairs: 1. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 2. Using the heat torch, apply heat to the high temperature heat shrink tubing. 3. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 4. Replace any reflective tape and clips that may have been removed during the repair. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4617 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4618 * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4619 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4620 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4621 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. Note: Some terminals have a lever that must be disengaged before the terminal can be released. * Insert the terminal release tool into the cavity. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4622 Special Tools * EL-38125-10 - Splice Sleeve Crimp Tool * EL-38125-580 - Terminal Release Tool Kit * J-38125-5 - Ultra Torch * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4623 (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4624 Auxiliary Power Outlet: Connector Views Component Connector End Views X80L Accessory Power Receptacle - Rear Console (KC7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4625 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Power Outlet Schematics Cigar Lighter and Power Outlet Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4626 Auxiliary Power Outlet: Description and Operation Power Outlets Description and Operation 12 Volt Power Outlet Receptacle Description and Operation The accessory power receptacle and cigarette lighter receptacle are supplied battery voltage when the ignition is ON or in the accessory position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Symptoms - Power Outlets Auxiliary Power Outlet: Testing and Inspection Symptoms - Power Outlets Symptoms - Power Outlets Visual/Physical Inspection * Inspect for aftermarket devices which can affect the operation of the power outlets. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories) * Inspect the accessible system components or the visible system components for obvious damage or for obvious conditions which can cause the symptom. Intermittent Electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) Symptom List Refer to Power Outlet Receptacle Malfunction (See: Power Outlet Receptacle Inoperative (120 VAC)) in order to diagnose the system. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Symptoms - Power Outlets > Page 4629 Auxiliary Power Outlet: Testing and Inspection Power Outlet Receptacle Inoperative (120 VAC) Power Outlet Receptacle Malfunction Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The accessory power receptacle and cigarette lighter receptacle are supplied B+ when the ignition is on or in the accessory position. Reference Information Schematic Reference Cigar Lighter/Power Outlet Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Description and Operation Power Outlets Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Circuit/System Verification Install a 12 V DC accessory into the X80 accessory power receptacle. Ignition ON, command the Accessory/Retained Accessory Power Relay Command ON and OFF with a scan tool. The K10 RAP relay should click and the 12 V DC accessory should have power. Circuit/System Testing 1. Ignition OFF, disconnect the KR70 auxiliary power relay. 2. Test for less than 10 ohm between the ground circuit terminal 86 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Symptoms - Power Outlets > Page 4630 3. Verify that a test lamp does not illuminate between the control circuit terminal 30 and ground. ‹› If the test lamp illuminates, test the control circuit for a short to voltage. 4. Ignition ON, verify that a test lamp illuminates between the ignition circuit terminal 85 and ground. ‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the K9 BCM. 5. Verify that a test lamp illuminates between the B+ circuit terminal 87 and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal and the B+ circuit fuse is open, test the control circuit terminal 30 for a short to ground. 6. Disconnect the harness connector at the inoperative X80 accessory power receptacle or E32 cigarette lighter receptacle. 7. Test for less than 10 ohm between the ground circuit terminal C and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 8. Connect the harness connector at the X80 accessory power receptacle or E32 cigarette lighter receptacle. 9. Connect a 20 A fused jumper wire between the KR70 auxiliary power relay B+ circuit terminal 87 and the control circuit terminal 30. Verify the 12 V DC accessory has power. ‹› If the 12 V DC does not have power, test the control circuit for a short to ground or an open/high resistance. If the circuit tests normal, test or replace the X80 accessory power receptacle or E32 cigarette lighter receptacle. 10. If all circuits test normal, test or replace the KR70 auxiliary power relay. Component Testing Relay Test 1. Ignition OFF, disconnect the KR70 auxiliary power relay. 2. Test for 60-180 ohm between terminals 85 and 86. ‹› If not within the specified range, replace the relay. 3. Test for infinite resistance between the following terminals: * 30 and 86 * 30 and 87 * 30 and 85 * 85 and 87 ‹› If not the specified value, replace the relay. 4. Install a 20 A fused jumper wire between relay terminal 85 and 12 V. Install a jumper wire between relay terminal 86 and ground. Test for less than 2 ohm between terminals 30 and 87. ‹› If greater than specified range, replace the relay. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Relay Replacement (Attached to Wire Harness) (See: Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) * Accessory Power Receptacle Replacement (See: Service and Repair/Accessory Power Receptacle Replacement) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Accessory Power Receptacle Retainer Replacement Auxiliary Power Outlet: Service and Repair Accessory Power Receptacle Retainer Replacement Accessory Power Receptacle Retainer Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Accessory Power Receptacle Retainer Replacement > Page 4633 Auxiliary Power Outlet: Service and Repair Accessory Power Receptacle Replacement Accessory Power Receptacle Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Page 4634 Auxiliary Power Outlet: Tools and Equipment Special Tools Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block Fuse: Locations Engine Compartment Fuse Block Engine Compartment Fuse Block To remove the fuse block cover, squeeze the clips and swing it up. Notice: Spilling liquid on any electrical component on the vehicle may damage it. Always keep the covers on any electrical component. Engine Compartment Fuse Block The vehicle may not be equipped with all of the fuses, relays, and features shown. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 4639 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 4640 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 4641 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 4642 Fuse: Locations Instrument Panel Fuse Block Instrument Panel Fuse Block The instrument panel fuse block is in the driver side of the instrument panel. To access the Fuses: 1. Open the fuse block cover by pulling out at the top. 2. Remove the lower edge of the cover. 3. Remove the cover. To reinstall the cover, reverse the steps above. Instrument Panel Fuse Block Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 4643 The vehicle may not be equipped with all of the fuses, relays, and features shown. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 4644 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood Fuse: Application and ID Fuse Block - Underhood Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 4647 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 4648 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 4649 X50A Fuse Block - Underhood Bottom View X50A Fuse Block - Underhood Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 4650 X50A Fuse Block - Underhood X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 4651 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 4652 X50A Fuse Block - Underhood X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 4653 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 4654 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 4655 X50B Fuse Block - Underhood Auxiliary X8 X50B Fuse Block - Underhood Auxiliary X9 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 4656 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 4657 Fuse: Application and ID Fuse Block - Battery Electrical Center Identification Views X50D Fuse Block - Battery Auxiliary Top View X50D Fuse Block - Battery Auxiliary Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 4658 X50D Fuse Block - Battery Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 4659 X50D Fuse Block - Battery Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 4660 X50D Fuse Block - Battery X3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 4661 X50D Fuse Block - Battery X4 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 4662 X50D Fuse Block - Battery X6 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 4663 Fuse: Application and ID Fuse Block - Instrument Panel Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 4664 X51A Fuse Block - Instrument Panel (Fuses) Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 4665 X51A Fuse Block - Instrument Panel (Relays) Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 4666 X51A Fuse Block - Instrument Panel Bottom View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 4667 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Harness Routing Views Fuse Block: Locations Harness Routing Views Harness Routing Views Forward Lamp Harness Routing 1 of 2 1 - X50A Fuse Block - Underhood 2 - X1 Fuse Block - Underhood X1 3 - X100 Body Harness and Body Front Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Harness Routing Views > Page 4672 Fuse Block: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 of 2 1 - X51A Fuse Block - Instrument Panel Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Harness Routing Views > Page 4673 Fuse Block: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left Side of the Engine Compartment Components 1 of 2 1 - X50D Fuse Block - Battery X5 2 - X50D Fuse Block - Battery X1 3 - X50D Fuse Block - Battery X6 4 - X50D Fuse Block - Battery X4 5 - X50D Fuse Block - Battery X3 6 - X50D Fuse Block Battery X2 7 - G122 Engine Compartment - Front Left 8 - X50D Fuse Block - Battery 9 - C1 Battery Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse Block Replacement Fuse Block: Service and Repair Fuse Block Replacement Fuse Block Replacement Removal Procedure 1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection) 2. Unlock the retaining tabs on the battery fuse box cover, and open the cover (1). 3. Remove the positive battery cable to starter nut (2). 4. Remove the positive battery cable to starter (3) from the battery. 5. Remove the positive battery cable. Refer to Battery Positive Cable Replacement (See: Battery/Battery Cable/Positive/Service and Repair/Battery Positive Cable Replacement) 6. Remove 2 body wiring harness nuts (1) and body wiring harness. 7. Remove fuse block (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse Block Replacement > Page 4676 Installation Procedure 1. Install fuse block. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 2. Install body wiring harness and 2 body wiring harness nuts. 4.7 Nm (42 lb in) 3. Install the positive battery cable. Refer to Battery Positive Cable Replacement (See: Battery/Battery Cable/Positive/Service and Repair/Battery Positive Cable Replacement) 4. Install the positive battery cable to starter (3). 5. Install the positive battery cable to starter nut (2). 9 Nm (80 lb in) 6. Close the battery fuse box cover (1) and lock the retaining tabs on the battery fuse box. 7. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse Block Replacement > Page 4677 Fuse Block: Service and Repair Front Compartment Fuse Block Replacement Front Compartment Fuse Block Replacement Removal Procedure 1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Remove the front compartment fuse block cover. Refer to Front Compartment Fuse Block Cover Replacement (See: Front Compartment Fuse Block Cover Replacement). Note: Bolts (1) are encapsulated on the end of threads so that they can not be removed from the fuse block. 3. Remove the 3 front compartment fuse block bolt (1) and the front compartment fuse block wiring harness supply (2). 4. Unlock retaining tabs and remove the front compartment fuse block (3). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse Block Replacement > Page 4678 1. Push down the 3 electrical connectors (3) before installation of the front compartment fuse block (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install front compartment fuse block wiring harness supply (1) and tighten to 12 Nm (106 lb in). 3. Install 3 front compartment fuse block bolt (1) and tighten to 6 Nm (53 lb in). 4. Install the front compartment fuse block cover. Refer to Front Compartment Fuse Block Cover Replacement (See: Front Compartment Fuse Block Cover Replacement). 5. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse Block Replacement > Page 4679 Fuse Block: Service and Repair Front Compartment Fuse Block Housing Replacement Front Compartment Fuse Block Housing Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse Block Replacement > Page 4680 Fuse Block: Service and Repair Front Compartment Fuse Block Cover Replacement Front Compartment Fuse Block Cover Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4685 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4686 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4687 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4688 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4689 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4690 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 4699 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 4705 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name Multiple Junction Connector: Diagrams Connector End Views By Name A3L Sunshade - Left Component Connector End Views A3L Sunshade - Left A3R Sunshade - Right Component Connector End Views A3R Sunshade - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4708 A7 Fuel Pump and Level Sensor Assembly Component Connector End Views A7 Fuel Pump and Level Sensor Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4709 A9A Outside Rearview Mirror - Driver Component Connector End Views A9A Outside Rearview Mirror - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4710 A9B Outside Rearview Mirror - Passenger Component Connector End Views A9B Outside Rearview Mirror - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4711 A10 Inside Rearview Mirror Component Connector End Views A10 Inside Rearview Mirror Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4712 A11 Radio X1 Component Connector End Views A11 Radio X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4713 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4714 A11 Radio X2 (UDN) Component Connector End Views A11 Radio X2 (UDN) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4715 A22 Radio Controls (UAG or UFD) Component Connector End Views A22 Radio Controls (UAG or UFD) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4716 A22 Radio Controls (UDN) Component Connector End Views A22 Radio Controls (UDN) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4717 A23D Door Latch Assembly - Driver Component Connector End Views A23D Door Latch Assembly - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4718 A23LR Door Latch Assembly - Left Rear Component Connector End Views A23LR Door Latch Assembly - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4719 A23P Door Latch Assembly - Passenger Component Connector End Views A23P Door Latch Assembly - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4720 A23RR Door Latch Assembly - Right Rear Component Connector End Views A23RR Door Latch Assembly - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4721 B5LF Wheel Speed Sensor - Left Front Component Connector End Views B5LF Wheel Speed Sensor - Left Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4722 B5LR Wheel Speed Sensor - Left Rear Component Connector End Views B5LR Wheel Speed Sensor - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4723 B5RF Wheel Speed Sensor - Right Front Component Connector End Views B5RF Wheel Speed Sensor - Right Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4724 B5RR Wheel Speed Sensor - Right Rear Component Connector End Views B5RR Wheel Speed Sensor - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4725 B9 Air Temperature Sensor - Ambient Component Connector End Views B9 Air Temperature Sensor - Ambient Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4726 B10B Ambient Light/Sunload Sensor Component Connector End Views B10B Ambient Light/Sunload Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4727 B18 Battery Current Sensor Component Connector End Views B18 Battery Current Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4728 B19C Brake Booster Vacuum Switch Component Connector End Views B19C Brake Booster Vacuum Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4729 B20 Brake Fluid Level Switch Component Connector End Views B20 Brake Fluid Level Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4730 B22 Brake Pedal Position Sensor Component Connector End Views B22 Brake Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4731 B25B Clutch Pedal Position Sensor Component Connector End Views B25B Clutch Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4732 B26 Crankshaft Position Sensor Component Connector End Views B26 Crankshaft Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4733 B55 Hood Ajar Switch Component Connector End Views B55 Hood Ajar Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4734 B59L Front Impact Sensor - Left Component Connector End Views B59L Front Impact Sensor - Left Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4735 B59R Front Impact Sensor - Right Component Connector End Views B59R Front Impact Sensor - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4736 B63LF Side Impact Sensor - Left Front Component Connector End Views B63LF Side Impact Sensor - Left Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4737 B63LR Side Impact Sensor - Left Rear Component Connector End Views B63LR Side Impact Sensor - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4738 B63RF Side Impact Sensor - Right Front Component Connector End Views B63RF Side Impact Sensor - Right Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4739 B63RR Side Impact Sensor - Right Rear Component Connector End Views B63RR Side Impact Sensor - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4740 B78E Rear Object Sensor - Left Middle (UD7) Component Connector End Views B78E Rear Object Sensor - Left Middle (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4741 B78F Rear Object Sensor - Right Middle (UD7) Component Connector End Views B78F Rear Object Sensor - Right Middle (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4742 B78G Rear Object Sensor - Left Outer (UD7) Component Connector End Views B78G Rear Object Sensor - Left Outer (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4743 B78H Rear Object Sensor - Right Outer (UD7) Component Connector End Views B78H Rear Object Sensor - Right Outer (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4744 B80 Park Brake Switch Component Connector End Views B80 Park Brake Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4745 B88D Seat Belt Switch - Driver Component Connector End Views B88D Seat Belt Switch - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4746 B88P Seat Belt Switch - Passenger Component Connector End Views B88P Seat Belt Switch - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4747 B107 Accelerator Pedal Position Sensor Component Connector End Views B107 Accelerator Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4748 B108 Air Quality Sensor Component Connector End Views B108 Air Quality Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4749 B119 Multi-Axis Acceleration Sensor Component Connector End Views B119 Multi-Axis Acceleration Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4750 B150 Fuel Tank Pressure Sensor Component Connector End Views B150 Fuel Tank Pressure Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4751 B160 Windshield Temperature and Inside Moisture Sensor Component Connector End Views B160 Windshield Temperature and Inside Moisture Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4752 C1 Battery Component Connector End Views C1 Battery Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4753 E2LF Side Marker Lamp - Left Front Component Connector End Views E2LF Side Marker Lamp - Left Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4754 E2RF Side Marker Lamp - Right Front Component Connector End Views E2RF Side Marker Lamp - Right Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4755 E4LR Turn Signal Lamp - Left Rear Component Connector End Views E4LR Turn Signal Lamp - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4756 E4N Park/Turn Signal Lamp - Left Component Connector End Views E4N Park/Turn Signal Lamp - Left Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4757 E4P Park/Turn Signal Lamp - Right Component Connector End Views E4P Park/Turn Signal Lamp - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4758 E4RR Turn Signal Lamp - Right Rear Component Connector End Views E4RR Turn Signal Lamp - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4759 E5A Backup Lamp - Left Component Connector End Views E5A Backup Lamp - Left Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4760 E5AA Tail/Stop Lamp - Left Component Connector End Views E5AA Tail/Stop Lamp - Left Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4761 E5AB Tail/Stop Lamp - Right Component Connector End Views E5AB Tail/Stop Lamp - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4762 E5B Backup Lamp - Right Component Connector End Views E5B Backup Lamp - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4763 E5E Tail Lamp - Left Component Connector End Views E5E Tail Lamp - Left Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4764 E5F Tail Lamp - Right Component Connector End Views E5F Tail Lamp - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4765 E6 Center High Mounted Brake Lamp Component Connector End Views E6 Center High Mounted Brake Lamp Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4766 E8S Rear Compartment Courtesy Lamp Component Connector End Views E8S Rear Compartment Courtesy Lamp Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4767 E13L Headlamp - Left Component Connector End Views E13L Headlamp - Left Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4768 E13R Headlamp - Right Component Connector End Views E13R Headlamp - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4769 E14A Seat Heating Element - Driver Back (KA1) Component Connector End Views E14A Seat Heating Element - Driver Back (KA1) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4770 E14C Seat Heating Element - Passenger Back (KA1) Component Connector End Views E14C Seat Heating Element - Passenger Back (KA1) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4771 E18 Rear Defogger Grid X1 Component Connector End Views E18 Rear Defogger Grid X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4772 E18 Rear Defogger Grid X2 Component Connector End Views E18 Rear Defogger Grid X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4773 E27 Instrument Panel Compartment Lamp Component Connector End Views E27 Instrument Panel Compartment Lamp Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4774 E29LF Fog Lamp - Left Front (T3U) Component Connector End Views E29LF Fog Lamp - Left Front (T3U) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4775 E29RF Fog Lamp - Right Front (T3U) Component Connector End Views E29RF Fog Lamp - Right Front (T3U) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4776 E32 Cigar Lighter Receptacle Component Connector End Views E32 Cigar Lighter Receptacle Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4777 F105 Passenger Instrument Panel Air Bag Component Connector End Views F105 Passenger Instrument Panel Air Bag Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4778 F105L Roof Rail Air Bag - Left Component Connector End Views F105L Roof Rail Air Bag - Left Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4779 F105R Roof Rail Air Bag - Right Component Connector End Views F105R Roof Rail Air Bag - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4780 F112D Seat Belt Pretensioner (Retractor) - Driver Component Connector End Views F112D Seat Belt Pretensioner (Retractor) - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4781 F112P Seat Belt Retractor Pretensioner - Passenger Component Connector End Views F112P Seat Belt Retractor Pretensioner - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4782 F113D Seat Belt Anchor Pretensioner - Driver Component Connector End Views F113D Seat Belt Anchor Pretensioner - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4783 F113P Seat Belt Anchor Pretensioner - Passenger Component Connector End Views F113P Seat Belt Anchor Pretensioner - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4784 G10 Cooling Fan Motor Component Connector End Views G10 Cooling Fan Motor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4785 G13 Generator X2 Component Connector End Views G13 Generator X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4786 G24 Windshield Washer Pump Component Connector End Views G24 Windshield Washer Pump Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4787 K8 Blower Motor Control Module X1 Component Connector End Views K8 Blower Motor Control Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4788 K8 Blower Motor Control Module X2 Component Connector End Views K8 Blower Motor Control Module X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4789 K9 Body Control Module X1 Component Connector End Views K9 Body Control Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4790 K9 Body Control Module X2 Component Connector End Views K9 Body Control Module X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4791 K9 Body Control Module X3 Component Connector End Views Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4792 K9 Body Control Module X3 K9 Body Control Module X4 Component Connector End Views Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4793 K9 Body Control Module X4 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4794 K9 Body Control Module X5 Component Connector End Views K9 Body Control Module X5 K9 Body Control Module X6 Component Connector End Views K9 Body Control Module X6 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4795 K9 Body Control Module X7 Component Connector End Views Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4796 K9 Body Control Module X7 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4797 K17 Electronic Brake Control Module Component Connector End Views K17 Electronic Brake Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4798 K29 Seat Heating Control Module X2 (KA1) Component Connector End Views K29 Seat Heating Control Module X2 (KA1) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4799 K29 Seat Heating Control Module X3 (KA1) Component Connector End Views K29 Seat Heating Control Module X3 (KA1) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4800 K33 HVAC Control Module X1 Component Connector End Views K33 HVAC Control Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4801 K33 HVAC Control Module X2 Component Connector End Views K33 HVAC Control Module X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4802 K33 HVAC Control Module X3 Component Connector End Views K33 HVAC Control Module X3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4803 K36 Inflatable Restraint Sensing and Diagnostic Module X1 Component Connector End Views K36 Inflatable Restraint Sensing and Diagnostic Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4804 K41 Parking Assist Control Module X1 (UD7) Component Connector End Views K41 Parking Assist Control Module X1 (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4805 K41 Parking Assist Control Module X2 (UD7) Component Connector End Views K41 Parking Assist Control Module X2 (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4806 K60 Steering Column Lock Control Module Component Connector End Views K60 Steering Column Lock Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4807 K61 Sunroof Control Module (CF5) Component Connector End Views K61 Sunroof Control Module (CF5) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4808 K77 Remote Control Door Lock Receiver Component Connector End Views K77 Remote Control Door Lock Receiver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4809 K89 Immobilizer Control Module Component Connector End Views K89 Immobilizer Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4810 M6 Air Temperature Door Actuator Component Connector End Views M6 Air Temperature Door Actuator Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4811 M8 Blower Motor Component Connector End Views M8 Blower Motor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4812 M9 Brake Booster Pump Motor Component Connector End Views M9 Brake Booster Pump Motor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4813 M37 Mode Door Actuator Component Connector End Views M37 Mode Door Actuator Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4814 M40 Rear Compartment Lid Latch Component Connector End Views M40 Rear Compartment Lid Latch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4815 M46 Recirculation Door Motor Component Connector End Views M46 Recirculation Door Motor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4816 M74D Window Motor - Driver (AEC) Component Connector End Views M74D Window Motor - Driver (AEC) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4817 M74D Window Motor - Driver (AXG) Component Connector End Views M74D Window Motor - Driver (AXG) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4818 M74LR Window Motor - Left Rear Component Connector End Views M74LR Window Motor - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4819 M74P Window Motor - Passenger Component Connector End Views M74P Window Motor - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4820 M74RR Window Motor - Right Rear Component Connector End Views M74RR Window Motor - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4821 M75 Windshield Wiper Motor Component Connector End Views M75 Windshield Wiper Motor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4822 M932 Ignition Lock Cylinder Control Solenoid Actuator (MH8) Component Connector End Views M932 Ignition Lock Cylinder Control Solenoid Actuator (MH8) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4823 P2 Automatic Transmission Shift Lever Position Indicator Component Connector End Views P2 Automatic Transmission Shift Lever Position Indicator Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4824 P12 Horn Component Connector End Views P12 Horn Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4825 P14 Passenger Air Bag Disable Indicator Component Connector End Views P14 Passenger Air Bag Disable Indicator Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4826 P16 Instrument Cluster Component Connector End Views P16 Instrument Cluster Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4827 P17 Info Display Module (UAG or UFD) Component Connector End Views P17 Info Display Module (UAG or UFD) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4828 P17 Info Display Module (UDN) Component Connector End Views P17 Info Display Module (UDN) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4829 P19B Speaker - Center Instrument Panel Component Connector End Views P19B Speaker - Center Instrument Panel Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4830 P19AA Speaker - Right Subwoofer Component Connector End Views P19AA Speaker - Right Subwoofer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4831 P19G Speaker - Left Front Component Connector End Views P19G Speaker - Left Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4832 P19H Speaker - Left Front Tweeter (UQA) Component Connector End Views P19H Speaker - Left Front Tweeter (UQA) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4833 P19K Speaker - Left Rear Component Connector End Views P19K Speaker - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4834 P19N Speaker - Left Subwoofer Component Connector End Views P19N Speaker - Left Subwoofer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4835 P19U Speaker - Right Front Component Connector End Views P19U Speaker - Right Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4836 P19V Speaker - Right Front Tweeter (UQA) Component Connector End Views P19V Speaker - Right Front Tweeter (UQA) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4837 P19X Speaker - Right Rear Component Connector End Views P19X Speaker - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4838 Q13 Evaporative Emission Vent Solenoid Valve Component Connector End Views Q13 Evaporative Emission Vent Solenoid Valve Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4839 S3 Automatic Transmission Shift Lever (MH8) Component Connector End Views S3 Automatic Transmission Shift Lever (MH8) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4840 S13D Door Lock Switch - Driver Component Connector End Views S13D Door Lock Switch - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4841 S26 Hazard Lamps Switch Component Connector End Views S26 Hazard Lamps Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4842 S30 Headlamp Switch Component Connector End Views S30 Headlamp Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4843 S34 HVAC Controls Switch Assembly Component Connector End Views S34 HVAC Controls Switch Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4844 S52 Outside Rearview Mirror Switch Component Connector End Views S52 Outside Rearview Mirror Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4845 S70R Steering Wheel Controls Switch - Right Component Connector End Views S70R Steering Wheel Controls Switch - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4846 S72 Sunroof Switch (CF5) Component Connector End Views S72 Sunroof Switch (CF5) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4847 S78 Turn Signal/Multi-Function Switch Component Connector End Views S78 Turn Signal/Multi-Function Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4848 S79D Window Switch - Driver (AEC) Component Connector End Views S79D Window Switch - Driver (AEC) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4849 S79D Window Switch - Driver (AXG) Component Connector End Views S79D Window Switch - Driver (AXG) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4850 S79LR Window Switch - Left Rear Component Connector End Views S79LR Window Switch - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4851 S79P Window Switch - Passenger Component Connector End Views S79P Window Switch - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4852 S79RR Window Switch - Right Rear Component Connector End Views S79RR Window Switch - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4853 S80 Window Wiper/Washer Switch Component Connector End Views S80 Window Wiper/Washer Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4854 S88 Sunroof Tilt Switch (CF5) Component Connector End Views S88 Sunroof Tilt Switch (CF5) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4855 T11 Multimedia Interface Module (KTA) Component Connector End Views T11 Multimedia Interface Module (KTA) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4856 X80L Accessory Power Receptacle - Rear Console (KC7) Component Connector End Views X80L Accessory Power Receptacle - Rear Console (KC7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4857 X83 Auxiliary Audio Input Component Connector End Views X83 Auxiliary Audio Input Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4858 X84 Data Link Connector Component Connector End Views X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4859 X85 Steering Wheel Air Bag Coil X1 Component Connector End Views X85 Steering Wheel Air Bag Coil X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4860 X85 Steering Wheel Air Bag Coil X2 Component Connector End Views X85 Steering Wheel Air Bag Coil X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4861 X85 Steering Wheel Air Bag Coil X3 Component Connector End Views X85 Steering Wheel Air Bag Coil X3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4862 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4863 Multiple Junction Connector: Diagrams Connector End Views By Number X100 Inline Harness Connector End Views X100 Body Harness to Forward Lamp Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4864 X102 Inline Harness Connector End Views X102 Engine Cooling Harness to Forward Lamp Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4865 X104 Inline Harness Connector End Views X104 Engine Cooling Harness to Forward Lamp Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4866 X110 Inline Harness Connector End Views X110 Body Harness to Engine Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4867 X114 Inline Harness Connector End Views X114 Power Steering Harness to Forward Lamp Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4868 X200 Inline Harness Connector End Views X200 Instrument Panel Harness to Body Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4869 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4870 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4871 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4872 X205 Inline Harness Connector End Views X205 Instrument Panel Harness to Body Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4873 X210 Inline Harness Connector End Views X210 Headliner Harness to Body Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4874 X211 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4875 Inline Harness Connector End Views X211 Headliner Harness to Body Harness X212 Inline Harness Connector End Views X212 Instrument Panel Harness to HVAC Harness (C68) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4876 X300 Inline Harness Connector End Views X300 Console Harness to Instrument Panel Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4877 X310 Inline Harness Connector End Views X310 Body Harness and Driver Seat Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4878 X315 Inline Harness Connector End Views X315 Body Harness and Passenger Seat Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4879 X320 Inline Harness Connector End Views X320 Body Harness to Curtain Air Bag Jumper Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4880 X321 Inline Harness Connector End Views X321 Body Harness to Curtain Air Bag Jumper Harness X401 Inline Harness Connector End Views X401 Fuel Tank Harness to Body Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4881 X402 Inline Harness Connector End Views X402 Rear Object Sensor to Harness Body Harness (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4882 X410 Inline Harness Connector End Views X410 Left Tail Lamp Harness to Body Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4883 X411 Inline Harness Connector End Views X411 Right Tail Lamp Harness to Body Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4884 X500 - X599 Inline Harness Connector End Views X500 Driver Door Harness to Body Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4885 X600 - X699 Inline Harness Connector End Views X600 Passenger Door Harness to Body Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4886 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4887 X700 - X799 Inline Harness Connector End Views X700 Left Rear Door Harness to Body Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4888 X800 - X899 Inline Harness Connector End Views X800 Right Rear Door Harness to Body Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4889 X900 Inline Harness Connector End Views X900 Rear Compartment Lid Harness to Body Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4890 X920 Inline Harness Connector End Views X920 License Lamp Harness to Rear Compartment Lid Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 4891 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations/A - Z Index) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 4896 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Fuse/Application and ID) to locate the electrical center where the relay exists. Note: * Always note the orientation of the relay. * If equipped with a notch style relay; observe the location of the notch on the old relay to verify the new relay is installed with the notch in the same location. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 4897 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Accessory Relay > Component Information > Locations Accessory Relay: Locations Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Accessory Relay > Component Information > Locations > Page 4902 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations/A - Z Index) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 4907 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Fuse/Application and ID) to locate the electrical center where the relay exists. Note: * Always note the orientation of the relay. * If equipped with a notch style relay; observe the location of the notch on the old relay to verify the new relay is installed with the notch in the same location. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 4908 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery Relay Box: Application and ID Fuse Block - Battery Electrical Center Identification Views X50D Fuse Block - Battery Auxiliary Top View X50D Fuse Block - Battery Auxiliary Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4913 X50D Fuse Block - Battery Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4914 X50D Fuse Block - Battery Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4915 X50D Fuse Block - Battery X3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4916 X50D Fuse Block - Battery X4 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4917 X50D Fuse Block - Battery X6 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4918 Relay Box: Application and ID Fuse Block - Underhood Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4919 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4920 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4921 X50A Fuse Block - Underhood Bottom View X50A Fuse Block - Underhood Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4922 X50A Fuse Block - Underhood X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4923 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4924 X50A Fuse Block - Underhood X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4925 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4926 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4927 X50B Fuse Block - Underhood Auxiliary X8 X50B Fuse Block - Underhood Auxiliary X9 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4928 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4929 Relay Box: Application and ID Fuse Block - Instrument Panel Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4930 X51A Fuse Block - Instrument Panel (Fuses) Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4931 X51A Fuse Block - Instrument Panel (Relays) Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4932 X51A Fuse Block - Instrument Panel Bottom View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4933 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery Relay Box: Application and ID Fuse Block - Battery Electrical Center Identification Views X50D Fuse Block - Battery Auxiliary Top View X50D Fuse Block - Battery Auxiliary Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4938 X50D Fuse Block - Battery Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4939 X50D Fuse Block - Battery Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4940 X50D Fuse Block - Battery X3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4941 X50D Fuse Block - Battery X4 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4942 X50D Fuse Block - Battery X6 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4943 Relay Box: Application and ID Fuse Block - Underhood Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4944 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4945 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4946 X50A Fuse Block - Underhood Bottom View X50A Fuse Block - Underhood Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4947 X50A Fuse Block - Underhood X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4948 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4949 X50A Fuse Block - Underhood X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4950 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4951 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4952 X50B Fuse Block - Underhood Auxiliary X8 X50B Fuse Block - Underhood Auxiliary X9 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4953 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4954 Relay Box: Application and ID Fuse Block - Instrument Panel Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4955 X51A Fuse Block - Instrument Panel (Fuses) Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4956 X51A Fuse Block - Instrument Panel (Relays) Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4957 X51A Fuse Block - Instrument Panel Bottom View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 4958 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4967 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4968 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4969 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 4974 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4980 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4981 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4982 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4987 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4988 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4989 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4990 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4991 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4992 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 4997 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5003 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5004 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5005 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5006 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5007 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5008 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Accessory Relay > Component Information > Locations Accessory Relay: Locations Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Accessory Relay > Component Information > Locations > Page 5013 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5018 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5019 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5020 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5021 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5022 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5023 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5024 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5025 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5026 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5027 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5028 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5029 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5030 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5031 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5032 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5033 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5034 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5035 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5036 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5037 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5038 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5039 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5040 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5041 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5042 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5043 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5044 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5045 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5046 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5047 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5048 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5049 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5050 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5051 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5052 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5053 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5054 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5055 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5056 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5057 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5058 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5059 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5060 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5061 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5062 Auxiliary Power Outlet: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5063 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5064 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5065 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools EL-35616-200 - Test Light - Probe Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A Digital Multimeter (DMM) should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The EL-35616-200 - kit is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5066 Testing for a Short to Voltage Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J-25070 - Heat Gun For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, to move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to the Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J-25070 - heat gun. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5067 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. In addition, circuit cooling spray can be used to cool down a component or circuit. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5068 For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Special Tools Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5069 EL-35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5070 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Using Snapshots in Global Diagnostic System (GDS) Overview Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5071 A snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. To record a snapshot in GDS, select, Record Snapshot, from the options at the top right portion of any of the various pages that allow snapshots to be taken (e.g. Data Display, Control Functions, etc.). When you are finished recording, select, Stop Snapshot recording. The snapshot will now be available for replay. Snapshot Replay The Snapshot Replay function allows reviews of previously recorded vehicle snapshot data. This information can be used in analysis of vehicle problems and detection of trigger error conditions. The graph function can be used to compare parameters to see if a component is functioning properly. Recorded snapshots can be selected for viewing by the following three methods: * Selecting a snapshot file from the Vehicle Home Page and clicking on the Review selection. * Double clicking on the selected snapshot from the Vehicle Home Page. * Entering the Tools selection from the Menu selection and selecting Snapshot replay. Next, open the Snapshot Manager. Double click on the snapshot file you wish to view or click on the Load Snapshot selection and select a snapshot file. Regardless of selection method, a File Loaded pop-up window will be displayed from the Snapshot Replay screen. Select OK from the pop-up window. Snapshot Play Functions There are several snapshot play functions that are used to replay recorded snapshots * The Play function is used to play the snapshot forward by clicking on this selection. A marker will move across the screen when this selection is used. All selections in this area turn grey when they are active. * The Pause function is used to pause play of the snapshot. When this selection is clicked a second time the snapshot will start playing where it left off. * The Stop function is used to stop playing the snapshot. The snapshot will start from the beginning, if Play is selected after using the Stop function. Time Control Time control is used to control the snapshot replay. This function allows selection of a specific time frame, display of different views, and control of display speed. The following functions can be selected directly under Time Control. * The Bookmark selection allows you to add a specific comment in the current display and return to this point in the future. When this option is selected, a pop-up window is displayed. Enter a bookmark name and select OK. * The Note Pad can be selected to add comments to the snapshot replay file at the current point of time. When this option is selected, a pop-up window is displayed. Enter a comment for the snapshot file and select OK. * The Load Snapshot (blue folder) opens a snapshot file and makes it ready for further analysis. This function is also available by clicking on an available snapshot file from the Snapshot Manager. * The Down Arrow displays all Time Control options when selected. Individual options can also be selected by clicking on the item you want. * The Snapshot Display Speed can be controlled by selecting this option. Slow speeds of 1/8X, 1/4X, and 1/2X can be selected. The real time speed can also be selected at 1. Faster speeds of 2X, 4X, and 8X can also be obtained by using this selection. View Selections Each View Selection provides a different way of displaying vehicle data for analysis. The following functions can be selected under Available Views: Note: The parameter name will be shown in the original language used for capture if no translation is available for the name. * Parameter List View - Displays incoming information from the snapshot file. The current value of the parameters is displayed on the screen. * Log View - Contains all the information from the snapshot file. All parameter values are listed in the order they were recorded. Specific parameters can be added or removed from a watchlist by clicking on the appropriate item. * State View - Shows the values of all parameters in a specific time frame. These values can be used for comparison with the trigger view. * Trigger View - Displays all system and user defined triggers. This function can be used when there is a combination of factors involved in a diagnostic problem. When a Trigger condition is met a caution triangle will be displayed on the screen. Triggers: * Load Triggers - Allows you to load a file containing trigger definitions. * Save Triggers - Allows you to save the trigger to your computer's hard drive. * Remove Trigger - Allows you to remove the current trigger. It will no longer be present. * Edit Trigger - Displays a pop-up window where you can modify the limits and parameters contained within a trigger. * Adds Trigger - Displays a pop-up window to configure a trigger. * DTC View - After the Play function is selected and this option is selected this function opens the list of recorded DTCs. * Line Graph View - Displays data that can be visualized against the time-axis. From this view, specific parameters can be selected for graphing by Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5072 checking the box under Selected. At the bottom of the graph there are four functions Zoom In (increase size), Zoom Out (decrease size), Bookmarks, and Pause Scrolling. Each of these functions can be accessed by clicking on them. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools EL-39200 - Digital Multimeter For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the EL-39200 - digital multimeter (DMM). This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. Note: The DMM must be used in order to perform the following procedure since the DMM can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5073 Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the DMM to the circuit. 2. Set the DMM to the V (AC) or V (DC) position. 3. Select the voltage range feature of the DMM in order to select the desired voltage range. Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 4. Select the MIN MAX function of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button until the MAX value is displayed and note the value. 8. Press the MIN MAX button until the MIN value is displayed and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools EL-35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5074 To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the EL-35616 - kit when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center. Use EL-35616 - kit to test for proper terminal contact. Failure to use EL-35616 - kit can result in improper diagnosis of the bussed electrical center. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal/terminated lead, verify that the retention force is significantly different between a known good terminal and the suspect terminal. Replace the female terminal in question. Flat Wire Connectors There are no serviceable parts for flat wire connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter into the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Ground Distribution Schematics). Temperature Sensitivity Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5075 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures - In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference or other types of electrical noise. Inspect for the following conditions: * A mis-routed harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc.-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc.-These accessories may create interference in other circuits while operating and the interference would disappear when the accessory is not operating. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5076 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, current, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 Mohm input impedance 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Current 1. Test a DC current range of 0.1 µA-10 A. 2. Test an AC current range of 0.1 µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 Mohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 Hz-199 k Hz Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5077 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 25 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the engine control module (ECM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the EL-39200. The DMM instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Special Tools EL 35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools EL 35616-20F - Fused Jumper Wire For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: A fused jumper may not protect solid state components from being damaged. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5078 The EL 35616-20F - Fused Jumper Wire includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool * J-38125-216 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5079 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5080 3. Slide the lever lock forward while pressing down on the lever lock release tab. 4. View showing depressing of the lever lock release tab. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5081 5. View of connector in released position. 6. Disconnect the connector from the component. 7. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 8. Release the rear lower half of the wiredress cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5082 9. Release the tabs that are holding the wiredress cover to the connector body. 10. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J-38125-216 can also be used to remove the nose piece. 11. Use the J-38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5083 12. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 13. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 14. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-561 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5084 4. Insert the J-38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-213 - Terminal Release Tool * J-38125-556 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5085 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5086 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5087 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J-38125-213 or the J-38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. 10. Reconnect the connector bodies. Bosch Connectors (0.64) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5088 Bosch Connectors (0.64) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5089 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5090 11. Insert the J-38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 13. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 14. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5091 Bosch Connectors (2.8 JPT) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-557 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J-38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5092 * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT) )Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock))FCI Connectors (SIR) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI (SIR)) * FEP Connectors (Steering Gear) (See: General Electrical Diagnostic Procedures/Connector Repairs/FEP Connectors (Steering Gear)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) Connector Anatomy Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5093 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5094 * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5095 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5096 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5097 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5098 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools EL-38125-580 - Terminal Release Tool Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5099 Terminal Removal Procedure Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull to Seat) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5100 Delphi Connectors (Pull To Seat) Special Tools EL-38125-580 - Terminal Release Tool Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Review the connector end view to determine the proper test probe and release tool. 5. Insert the release tool into the front of the connector body. 6. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 3. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-21 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5101 Terminal Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5102 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5103 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wire dress cover and pull the lever over and past the locks. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5104 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5105 Note: Be careful not to angle or rock the J-38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J-38125-21 tool into the round canal between the terminals cavities at the front of the connector. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5106 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5107 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5108 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5109 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J-38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5110 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-10A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J-38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5111 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (12-Way) Delphi Connectors (12-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5112 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5113 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5114 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J-38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5115 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (Steering Gear) Delphi Connectors (Steering Gear) Removal Procedure 1. Use a small flat-bladed tool to release the locking tab on the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5116 2. Push down the locking tab to release the connector. The small flat-bladed tool may need to be pushed down and angled back slightly to depress the locking tab. Pull on the connector body while releasing the locking tab to disconnect the connector. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-556 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5117 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5118 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. 7. For the larger terminals insert the J-38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J-38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5119 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 9. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 10. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. FCI (SIR) FCI Connectors (SIR) Removal Procedure Note: The orange connector position assurance (CPA) must be released first to disconnect or to connect the connector. 1. Lift the orange CPA vertically (avoid lifting on an angle to the connector) approximately 4 mm to release the connector. Use a small flat-bladed Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5120 tool to help release the orange CPA. The orange CPA can also be released manually without any tools. 2. Grab the connector on both sides and lift the connector vertically to disconnect the connector. Installation Procedure 1. Lift the orange CPA vertically approximately 4 mm before installing the connector. Use a small flat-bladed tool to help release the orange CPA. The orange CPA can also be released manually without any tools. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5121 2. Line up the connector key tabs with the initiator key slots. Grab the connector on both sides and push the connector down into the initiator connector sub assembly until fully seated. 3. After the connector is fully seated, push down the orange CPA with your thumb. Push down until the orange CPA is touching the yellow cover on the connector. FEP Connectors (Steering Gear) FEP Connectors (Steering Gear) Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5122 1. Use a small flat-bladed tool to release the locking tab on the connector. 2. Push down the locking tab to release the connector. The small flat-bladed tool may need to be pushed down and angled back slightly to depress the locking tab. Pull on the connector body while releasing the locking tab to disconnect the connector. JST Connectors JST Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5123 The JST connector family consists of seven unique connector housings differentiated by color and keying. This connector family is designed to use both 0.64 and 2.8 sized terminals. 1. While depressing the lock, remove the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5124 2. Unlock the terminal position assurance (TPA): * Position connector as shown (above) and locate TPA staging cavities. * Using connector terminal release tool J-38125-553 (1) lift the TPA into the staged position (figure 1). Perform this step on both sides of the TPA. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5125 * You will feel the TPA click into place when fully extended into the staged position. The figure above shows the TPA (1) in the staged position. 3. Release the terminal from the connector: * Position the connector as shown (above) and locate the terminal release entry canal (1) of the suspect terminal. * Insert the connector terminal release tool J-38125-553 into the entry canal with the angled side of the tool facing the connector wall containing cavity 4 (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5126 * The cavity on the left (1) is a 2.8 mm cavity and the cavity on the right (2) is a 0.64 mm cavity. * Place the tip of the connector terminal release tool onto the connector lance (3) and deflect the lance to the right (5) to release the lock. Hold this released position. * Holding the lance in the released position, slightly pull on the suspect terminal to remove it from the connector housing. The side TPA (4) is a secondary lock. 4. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 5. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-24 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5127 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5128 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5129 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5130 8. Use the J-38125-24 or the J-38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-28 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5131 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5132 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J-38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5133 locked in place by gently pulling on the wire. 3. Locate the TPA. 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5134 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-213 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5135 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5136 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5137 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J-38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5138 Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5139 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J-38125-12A - tool into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5140 7. Pressing the J-38125-12A - tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool * J-38125-13A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-bladed tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5141 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-bladed tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J-38125-13A - tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J-38125-12A - tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5142 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5143 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5144 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5145 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5146 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5147 6. Use the J-38125-12A tool to release the terminals by pressing on the tang. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool * J-38125-212 - Terminal Release Tool * J-38125-216 - Terminal Release Tool * J-38125-221 - Terminal Release Tool * J-38125-560 - Terminal Release Tool * J-38125-566 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5148 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5149 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5150 Note: During assembly the terminal position assurance (TPA) will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J-38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5151 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5152 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5153 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J-38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5154 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5155 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5156 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5157 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5158 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. 22. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 23. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool * J-38125-212 - Terminal Release Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5159 * J-38125-556 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5160 Note: Terminal position assurance (TPA) is keyed and can only be inserted in one direction. 3. Using terminal release tool J-38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5161 5. Using terminal release tool J-38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5162 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5163 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5164 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5165 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5166 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5167 * J-38125-552 - Terminal Release Tool * J-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5168 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5169 5. Once the nose piece retainers are relaxed, use the J-38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5170 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5171 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5172 2. Insert the J-38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5173 5. Insert the J-38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-24 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5174 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5175 5. While pushing the terminal forward, insert the J-38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5176 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J-38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5177 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-215 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5178 1. While depressing the lock, pull the two connector halves apart. Note: The terminal position assurance (TPA) is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the TPA towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5179 4. View of the female half of the connector with male terminals. 5. Use the J-38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. 6. View of the female half of the connector with male terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5180 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 9. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 10. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Repairing Connector Terminals (Terminated Lead Repair) Repairing Connector Terminals (Terminated Lead Repair) Special Tools * EL-38125-10 - Splice Sleeve Crimp Tool * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs procedures. For high temperature wiring repairs, refer to High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs). Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to in Splicing Copper Wire Using Splice Sleeves to identify the correct DuraSeal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Repairing Connector Terminals (Terminal Repair) Repairing Connector Terminals (Terminal Repair) Special Tools * J-38125 - Terminal Repair Kit * J-38125-6 - Crimp Tool * J-38125-7 - Crimp Tool * J-38125-8 - Crimp Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5181 * J-38125-64 - Crimp Tool * J-38125-101 - Crimp Tool * J-38125-641 - Crimp Tool * J-38125-642 - Crimp Tool * J-38125-643 - Crimp Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Use the following repair procedures to repair each type of terminal: * For push to seat terminals, refer to Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)). * For pull to seat terminals, refer to Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)). Note: The first step for all terminal repairs is to find the connector end view in SI. Cable Seal Terminals 1. Cut off the terminal between the core and the insulation crimp to minimize any wire loss. 2. Remove the old seal. 3. Apply the correct cable seal, per the wire gauge size, from the kit. Slide the seal back along the wire to enable removal of the insulation. 4. To minimize wire loss, remove only the insulation required. 5. Using the connector end view, determine the correct crimp tool and crimp jaw. 6. Align the seal with the end of the cable insulation. 7. Position the stripped wire and seal in the terminal. 8. Hand Crimp the core wings first. 9. Hand Crimp the insulation wings around the seal and the cable. 10. Solder all of the hand crimp terminals except the Micro-Pack 100 and 0.64 sizes. Unsealed Terminals 1. Cut off the terminal between the core and the insulation crimp to minimize any wire loss. 2. To minimize wire loss, remove only the insulation required. 3. Position the stripped wire in the terminal. 4. Hand Crimp the core wings first. 5. Hand Crimp the insulation wings around the cable. 6. Solder all of the hand crimp terminals except the Micro-Pack 100 and 0.64 sizes. Micro-Pack 100W Size Terminal The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5182 the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Micro 0.64 Size Terminal The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J-38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J-38125-64 crimping tool is also designed to crimp Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5183 both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5184 7. Place the terminal into the appropriate cavity and assemble the connector. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5185 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch Special Tool * DuraSeal splice sleeves * A wire stripping tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5186 For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A terminated lead can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs in the service information connector end views or the vehicle schematics in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and EL-38125-10 - tool. For wiring repair, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. High Temperature Wiring Repairs High Temperature Wiring Repairs Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5187 Note: All wiring repairs need to be 200 mm from the heat zone. Areas of consideration would be any area located near the exhaust manifolds, catalytic converter, exhaust pipes, and turbocharged engines. Items Required * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * Terminated leads or pigtails * The correct tools to remove the terminals from the connectors Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing. * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Note: High temperature areas would be areas located near exhaust manifolds, catalytic converters, exhaust pipes, and turbocharged engines. Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5188 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. Terminated leads can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs in the service information connector end views or the vehicle schematics in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5189 the DuraSeal splice sleeves and EL-38125-10 - tool. For wiring repair, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). For connector position assurance (CPA), refer to Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks). For terminal position assurance (TPA), refer to Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks). Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except Tefzel and coaxial. Use DuraSeal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert to regional wiring gauge size. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. For high temperature wiring, slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5190 tubing will not interfere with the splice procedure. 5. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 6. Use the splice sleeve crimp tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 7. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 8. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 9. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4, 6 and 15 for the opposite end of the splice. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5191 10. Using the heat torch, apply heat to the crimped area of the barrel. 11. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. High Temperature Wiring Repairs Use the following procedures to perform high temperature wiring repairs: 1. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 2. Using the heat torch, apply heat to the high temperature heat shrink tubing. 3. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 4. Replace any reflective tape and clips that may have been removed during the repair. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5192 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5193 * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5194 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5195 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5196 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. Note: Some terminals have a lever that must be disengaged before the terminal can be released. * Insert the terminal release tool into the cavity. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5197 Special Tools * EL-38125-10 - Splice Sleeve Crimp Tool * EL-38125-580 - Terminal Release Tool Kit * J-38125-5 - Ultra Torch * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5198 (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5199 Auxiliary Power Outlet: Connector Views Component Connector End Views X80L Accessory Power Receptacle - Rear Console (KC7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5200 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Power Outlet Schematics Cigar Lighter and Power Outlet Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5201 Auxiliary Power Outlet: Description and Operation Power Outlets Description and Operation 12 Volt Power Outlet Receptacle Description and Operation The accessory power receptacle and cigarette lighter receptacle are supplied battery voltage when the ignition is ON or in the accessory position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Symptoms - Power Outlets Auxiliary Power Outlet: Testing and Inspection Symptoms - Power Outlets Symptoms - Power Outlets Visual/Physical Inspection * Inspect for aftermarket devices which can affect the operation of the power outlets. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories) * Inspect the accessible system components or the visible system components for obvious damage or for obvious conditions which can cause the symptom. Intermittent Electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) Symptom List Refer to Power Outlet Receptacle Malfunction (See: Power Outlet Receptacle Inoperative (120 VAC)) in order to diagnose the system. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Symptoms - Power Outlets > Page 5204 Auxiliary Power Outlet: Testing and Inspection Power Outlet Receptacle Inoperative (120 VAC) Power Outlet Receptacle Malfunction Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The accessory power receptacle and cigarette lighter receptacle are supplied B+ when the ignition is on or in the accessory position. Reference Information Schematic Reference Cigar Lighter/Power Outlet Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Description and Operation Power Outlets Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Circuit/System Verification Install a 12 V DC accessory into the X80 accessory power receptacle. Ignition ON, command the Accessory/Retained Accessory Power Relay Command ON and OFF with a scan tool. The K10 RAP relay should click and the 12 V DC accessory should have power. Circuit/System Testing 1. Ignition OFF, disconnect the KR70 auxiliary power relay. 2. Test for less than 10 ohm between the ground circuit terminal 86 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Symptoms - Power Outlets > Page 5205 3. Verify that a test lamp does not illuminate between the control circuit terminal 30 and ground. ‹› If the test lamp illuminates, test the control circuit for a short to voltage. 4. Ignition ON, verify that a test lamp illuminates between the ignition circuit terminal 85 and ground. ‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the K9 BCM. 5. Verify that a test lamp illuminates between the B+ circuit terminal 87 and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal and the B+ circuit fuse is open, test the control circuit terminal 30 for a short to ground. 6. Disconnect the harness connector at the inoperative X80 accessory power receptacle or E32 cigarette lighter receptacle. 7. Test for less than 10 ohm between the ground circuit terminal C and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 8. Connect the harness connector at the X80 accessory power receptacle or E32 cigarette lighter receptacle. 9. Connect a 20 A fused jumper wire between the KR70 auxiliary power relay B+ circuit terminal 87 and the control circuit terminal 30. Verify the 12 V DC accessory has power. ‹› If the 12 V DC does not have power, test the control circuit for a short to ground or an open/high resistance. If the circuit tests normal, test or replace the X80 accessory power receptacle or E32 cigarette lighter receptacle. 10. If all circuits test normal, test or replace the KR70 auxiliary power relay. Component Testing Relay Test 1. Ignition OFF, disconnect the KR70 auxiliary power relay. 2. Test for 60-180 ohm between terminals 85 and 86. ‹› If not within the specified range, replace the relay. 3. Test for infinite resistance between the following terminals: * 30 and 86 * 30 and 87 * 30 and 85 * 85 and 87 ‹› If not the specified value, replace the relay. 4. Install a 20 A fused jumper wire between relay terminal 85 and 12 V. Install a jumper wire between relay terminal 86 and ground. Test for less than 2 ohm between terminals 30 and 87. ‹› If greater than specified range, replace the relay. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Relay Replacement (Attached to Wire Harness) (See: Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) * Accessory Power Receptacle Replacement (See: Service and Repair/Accessory Power Receptacle Replacement) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Accessory Power Receptacle Retainer Replacement Auxiliary Power Outlet: Service and Repair Accessory Power Receptacle Retainer Replacement Accessory Power Receptacle Retainer Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Accessory Power Receptacle Retainer Replacement > Page 5208 Auxiliary Power Outlet: Service and Repair Accessory Power Receptacle Replacement Accessory Power Receptacle Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Page 5209 Auxiliary Power Outlet: Tools and Equipment Special Tools Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block Fuse: Locations Engine Compartment Fuse Block Engine Compartment Fuse Block To remove the fuse block cover, squeeze the clips and swing it up. Notice: Spilling liquid on any electrical component on the vehicle may damage it. Always keep the covers on any electrical component. Engine Compartment Fuse Block The vehicle may not be equipped with all of the fuses, relays, and features shown. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 5214 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 5215 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 5216 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 5217 Fuse: Locations Instrument Panel Fuse Block Instrument Panel Fuse Block The instrument panel fuse block is in the driver side of the instrument panel. To access the Fuses: 1. Open the fuse block cover by pulling out at the top. 2. Remove the lower edge of the cover. 3. Remove the cover. To reinstall the cover, reverse the steps above. Instrument Panel Fuse Block Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 5218 The vehicle may not be equipped with all of the fuses, relays, and features shown. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine Compartment Fuse Block > Page 5219 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood Fuse: Application and ID Fuse Block - Underhood Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 5222 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 5223 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 5224 X50A Fuse Block - Underhood Bottom View X50A Fuse Block - Underhood Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 5225 X50A Fuse Block - Underhood X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 5226 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 5227 X50A Fuse Block - Underhood X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 5228 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 5229 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 5230 X50B Fuse Block - Underhood Auxiliary X8 X50B Fuse Block - Underhood Auxiliary X9 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 5231 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 5232 Fuse: Application and ID Fuse Block - Battery Electrical Center Identification Views X50D Fuse Block - Battery Auxiliary Top View X50D Fuse Block - Battery Auxiliary Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 5233 X50D Fuse Block - Battery Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 5234 X50D Fuse Block - Battery Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 5235 X50D Fuse Block - Battery X3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 5236 X50D Fuse Block - Battery X4 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 5237 X50D Fuse Block - Battery X6 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 5238 Fuse: Application and ID Fuse Block - Instrument Panel Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 5239 X51A Fuse Block - Instrument Panel (Fuses) Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 5240 X51A Fuse Block - Instrument Panel (Relays) Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 5241 X51A Fuse Block - Instrument Panel Bottom View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 5242 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Harness Routing Views Fuse Block: Locations Harness Routing Views Harness Routing Views Forward Lamp Harness Routing 1 of 2 1 - X50A Fuse Block - Underhood 2 - X1 Fuse Block - Underhood X1 3 - X100 Body Harness and Body Front Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Harness Routing Views > Page 5247 Fuse Block: Locations Instrument Panel/Center Console Component Views Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 of 2 1 - X51A Fuse Block - Instrument Panel Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Harness Routing Views > Page 5248 Fuse Block: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left Side of the Engine Compartment Components 1 of 2 1 - X50D Fuse Block - Battery X5 2 - X50D Fuse Block - Battery X1 3 - X50D Fuse Block - Battery X6 4 - X50D Fuse Block - Battery X4 5 - X50D Fuse Block - Battery X3 6 - X50D Fuse Block Battery X2 7 - G122 Engine Compartment - Front Left 8 - X50D Fuse Block - Battery 9 - C1 Battery Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse Block Replacement Fuse Block: Service and Repair Fuse Block Replacement Fuse Block Replacement Removal Procedure 1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection) 2. Unlock the retaining tabs on the battery fuse box cover, and open the cover (1). 3. Remove the positive battery cable to starter nut (2). 4. Remove the positive battery cable to starter (3) from the battery. 5. Remove the positive battery cable. Refer to Battery Positive Cable Replacement (See: Starting and Charging/Battery/Battery Cable/Positive/Service and Repair/Battery Positive Cable Replacement) 6. Remove 2 body wiring harness nuts (1) and body wiring harness. 7. Remove fuse block (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse Block Replacement > Page 5251 Installation Procedure 1. Install fuse block. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 2. Install body wiring harness and 2 body wiring harness nuts. 4.7 Nm (42 lb in) 3. Install the positive battery cable. Refer to Battery Positive Cable Replacement (See: Starting and Charging/Battery/Battery Cable/Positive/Service and Repair/Battery Positive Cable Replacement) 4. Install the positive battery cable to starter (3). 5. Install the positive battery cable to starter nut (2). 9 Nm (80 lb in) 6. Close the battery fuse box cover (1) and lock the retaining tabs on the battery fuse box. 7. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse Block Replacement > Page 5252 Fuse Block: Service and Repair Front Compartment Fuse Block Replacement Front Compartment Fuse Block Replacement Removal Procedure 1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Remove the front compartment fuse block cover. Refer to Front Compartment Fuse Block Cover Replacement (See: Front Compartment Fuse Block Cover Replacement). Note: Bolts (1) are encapsulated on the end of threads so that they can not be removed from the fuse block. 3. Remove the 3 front compartment fuse block bolt (1) and the front compartment fuse block wiring harness supply (2). 4. Unlock retaining tabs and remove the front compartment fuse block (3). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse Block Replacement > Page 5253 1. Push down the 3 electrical connectors (3) before installation of the front compartment fuse block (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install front compartment fuse block wiring harness supply (1) and tighten to 12 Nm (106 lb in). 3. Install 3 front compartment fuse block bolt (1) and tighten to 6 Nm (53 lb in). 4. Install the front compartment fuse block cover. Refer to Front Compartment Fuse Block Cover Replacement (See: Front Compartment Fuse Block Cover Replacement). 5. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse Block Replacement > Page 5254 Fuse Block: Service and Repair Front Compartment Fuse Block Housing Replacement Front Compartment Fuse Block Housing Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse Block Replacement > Page 5255 Fuse Block: Service and Repair Front Compartment Fuse Block Cover Replacement Front Compartment Fuse Block Cover Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 5260 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 5261 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 5262 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 5263 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 5264 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 5265 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power > Page 5274 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 5280 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name Multiple Junction Connector: Diagrams Connector End Views By Name A3L Sunshade - Left Component Connector End Views A3L Sunshade - Left A3R Sunshade - Right Component Connector End Views A3R Sunshade - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5283 A7 Fuel Pump and Level Sensor Assembly Component Connector End Views A7 Fuel Pump and Level Sensor Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5284 A9A Outside Rearview Mirror - Driver Component Connector End Views A9A Outside Rearview Mirror - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5285 A9B Outside Rearview Mirror - Passenger Component Connector End Views A9B Outside Rearview Mirror - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5286 A10 Inside Rearview Mirror Component Connector End Views A10 Inside Rearview Mirror Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5287 A11 Radio X1 Component Connector End Views A11 Radio X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5288 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5289 A11 Radio X2 (UDN) Component Connector End Views A11 Radio X2 (UDN) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5290 A22 Radio Controls (UAG or UFD) Component Connector End Views A22 Radio Controls (UAG or UFD) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5291 A22 Radio Controls (UDN) Component Connector End Views A22 Radio Controls (UDN) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5292 A23D Door Latch Assembly - Driver Component Connector End Views A23D Door Latch Assembly - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5293 A23LR Door Latch Assembly - Left Rear Component Connector End Views A23LR Door Latch Assembly - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5294 A23P Door Latch Assembly - Passenger Component Connector End Views A23P Door Latch Assembly - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5295 A23RR Door Latch Assembly - Right Rear Component Connector End Views A23RR Door Latch Assembly - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5296 B5LF Wheel Speed Sensor - Left Front Component Connector End Views B5LF Wheel Speed Sensor - Left Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5297 B5LR Wheel Speed Sensor - Left Rear Component Connector End Views B5LR Wheel Speed Sensor - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5298 B5RF Wheel Speed Sensor - Right Front Component Connector End Views B5RF Wheel Speed Sensor - Right Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5299 B5RR Wheel Speed Sensor - Right Rear Component Connector End Views B5RR Wheel Speed Sensor - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5300 B9 Air Temperature Sensor - Ambient Component Connector End Views B9 Air Temperature Sensor - Ambient Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5301 B10B Ambient Light/Sunload Sensor Component Connector End Views B10B Ambient Light/Sunload Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5302 B18 Battery Current Sensor Component Connector End Views B18 Battery Current Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5303 B19C Brake Booster Vacuum Switch Component Connector End Views B19C Brake Booster Vacuum Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5304 B20 Brake Fluid Level Switch Component Connector End Views B20 Brake Fluid Level Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5305 B22 Brake Pedal Position Sensor Component Connector End Views B22 Brake Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5306 B25B Clutch Pedal Position Sensor Component Connector End Views B25B Clutch Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5307 B26 Crankshaft Position Sensor Component Connector End Views B26 Crankshaft Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5308 B55 Hood Ajar Switch Component Connector End Views B55 Hood Ajar Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5309 B59L Front Impact Sensor - Left Component Connector End Views B59L Front Impact Sensor - Left Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5310 B59R Front Impact Sensor - Right Component Connector End Views B59R Front Impact Sensor - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5311 B63LF Side Impact Sensor - Left Front Component Connector End Views B63LF Side Impact Sensor - Left Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5312 B63LR Side Impact Sensor - Left Rear Component Connector End Views B63LR Side Impact Sensor - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5313 B63RF Side Impact Sensor - Right Front Component Connector End Views B63RF Side Impact Sensor - Right Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5314 B63RR Side Impact Sensor - Right Rear Component Connector End Views B63RR Side Impact Sensor - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5315 B78E Rear Object Sensor - Left Middle (UD7) Component Connector End Views B78E Rear Object Sensor - Left Middle (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5316 B78F Rear Object Sensor - Right Middle (UD7) Component Connector End Views B78F Rear Object Sensor - Right Middle (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5317 B78G Rear Object Sensor - Left Outer (UD7) Component Connector End Views B78G Rear Object Sensor - Left Outer (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5318 B78H Rear Object Sensor - Right Outer (UD7) Component Connector End Views B78H Rear Object Sensor - Right Outer (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5319 B80 Park Brake Switch Component Connector End Views B80 Park Brake Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5320 B88D Seat Belt Switch - Driver Component Connector End Views B88D Seat Belt Switch - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5321 B88P Seat Belt Switch - Passenger Component Connector End Views B88P Seat Belt Switch - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5322 B107 Accelerator Pedal Position Sensor Component Connector End Views B107 Accelerator Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5323 B108 Air Quality Sensor Component Connector End Views B108 Air Quality Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5324 B119 Multi-Axis Acceleration Sensor Component Connector End Views B119 Multi-Axis Acceleration Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5325 B150 Fuel Tank Pressure Sensor Component Connector End Views B150 Fuel Tank Pressure Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5326 B160 Windshield Temperature and Inside Moisture Sensor Component Connector End Views B160 Windshield Temperature and Inside Moisture Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5327 C1 Battery Component Connector End Views C1 Battery Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5328 E2LF Side Marker Lamp - Left Front Component Connector End Views E2LF Side Marker Lamp - Left Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5329 E2RF Side Marker Lamp - Right Front Component Connector End Views E2RF Side Marker Lamp - Right Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5330 E4LR Turn Signal Lamp - Left Rear Component Connector End Views E4LR Turn Signal Lamp - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5331 E4N Park/Turn Signal Lamp - Left Component Connector End Views E4N Park/Turn Signal Lamp - Left Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5332 E4P Park/Turn Signal Lamp - Right Component Connector End Views E4P Park/Turn Signal Lamp - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5333 E4RR Turn Signal Lamp - Right Rear Component Connector End Views E4RR Turn Signal Lamp - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5334 E5A Backup Lamp - Left Component Connector End Views E5A Backup Lamp - Left Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5335 E5AA Tail/Stop Lamp - Left Component Connector End Views E5AA Tail/Stop Lamp - Left Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5336 E5AB Tail/Stop Lamp - Right Component Connector End Views E5AB Tail/Stop Lamp - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5337 E5B Backup Lamp - Right Component Connector End Views E5B Backup Lamp - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5338 E5E Tail Lamp - Left Component Connector End Views E5E Tail Lamp - Left Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5339 E5F Tail Lamp - Right Component Connector End Views E5F Tail Lamp - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5340 E6 Center High Mounted Brake Lamp Component Connector End Views E6 Center High Mounted Brake Lamp Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5341 E8S Rear Compartment Courtesy Lamp Component Connector End Views E8S Rear Compartment Courtesy Lamp Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5342 E13L Headlamp - Left Component Connector End Views E13L Headlamp - Left Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5343 E13R Headlamp - Right Component Connector End Views E13R Headlamp - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5344 E14A Seat Heating Element - Driver Back (KA1) Component Connector End Views E14A Seat Heating Element - Driver Back (KA1) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5345 E14C Seat Heating Element - Passenger Back (KA1) Component Connector End Views E14C Seat Heating Element - Passenger Back (KA1) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5346 E18 Rear Defogger Grid X1 Component Connector End Views E18 Rear Defogger Grid X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5347 E18 Rear Defogger Grid X2 Component Connector End Views E18 Rear Defogger Grid X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5348 E27 Instrument Panel Compartment Lamp Component Connector End Views E27 Instrument Panel Compartment Lamp Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5349 E29LF Fog Lamp - Left Front (T3U) Component Connector End Views E29LF Fog Lamp - Left Front (T3U) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5350 E29RF Fog Lamp - Right Front (T3U) Component Connector End Views E29RF Fog Lamp - Right Front (T3U) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5351 E32 Cigar Lighter Receptacle Component Connector End Views E32 Cigar Lighter Receptacle Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5352 F105 Passenger Instrument Panel Air Bag Component Connector End Views F105 Passenger Instrument Panel Air Bag Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5353 F105L Roof Rail Air Bag - Left Component Connector End Views F105L Roof Rail Air Bag - Left Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5354 F105R Roof Rail Air Bag - Right Component Connector End Views F105R Roof Rail Air Bag - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5355 F112D Seat Belt Pretensioner (Retractor) - Driver Component Connector End Views F112D Seat Belt Pretensioner (Retractor) - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5356 F112P Seat Belt Retractor Pretensioner - Passenger Component Connector End Views F112P Seat Belt Retractor Pretensioner - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5357 F113D Seat Belt Anchor Pretensioner - Driver Component Connector End Views F113D Seat Belt Anchor Pretensioner - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5358 F113P Seat Belt Anchor Pretensioner - Passenger Component Connector End Views F113P Seat Belt Anchor Pretensioner - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5359 G10 Cooling Fan Motor Component Connector End Views G10 Cooling Fan Motor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5360 G13 Generator X2 Component Connector End Views G13 Generator X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5361 G24 Windshield Washer Pump Component Connector End Views G24 Windshield Washer Pump Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5362 K8 Blower Motor Control Module X1 Component Connector End Views K8 Blower Motor Control Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5363 K8 Blower Motor Control Module X2 Component Connector End Views K8 Blower Motor Control Module X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5364 K9 Body Control Module X1 Component Connector End Views K9 Body Control Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5365 K9 Body Control Module X2 Component Connector End Views K9 Body Control Module X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5366 K9 Body Control Module X3 Component Connector End Views Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5367 K9 Body Control Module X3 K9 Body Control Module X4 Component Connector End Views Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5368 K9 Body Control Module X4 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5369 K9 Body Control Module X5 Component Connector End Views K9 Body Control Module X5 K9 Body Control Module X6 Component Connector End Views K9 Body Control Module X6 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5370 K9 Body Control Module X7 Component Connector End Views Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5371 K9 Body Control Module X7 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5372 K17 Electronic Brake Control Module Component Connector End Views K17 Electronic Brake Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5373 K29 Seat Heating Control Module X2 (KA1) Component Connector End Views K29 Seat Heating Control Module X2 (KA1) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5374 K29 Seat Heating Control Module X3 (KA1) Component Connector End Views K29 Seat Heating Control Module X3 (KA1) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5375 K33 HVAC Control Module X1 Component Connector End Views K33 HVAC Control Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5376 K33 HVAC Control Module X2 Component Connector End Views K33 HVAC Control Module X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5377 K33 HVAC Control Module X3 Component Connector End Views K33 HVAC Control Module X3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5378 K36 Inflatable Restraint Sensing and Diagnostic Module X1 Component Connector End Views K36 Inflatable Restraint Sensing and Diagnostic Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5379 K41 Parking Assist Control Module X1 (UD7) Component Connector End Views K41 Parking Assist Control Module X1 (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5380 K41 Parking Assist Control Module X2 (UD7) Component Connector End Views K41 Parking Assist Control Module X2 (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5381 K60 Steering Column Lock Control Module Component Connector End Views K60 Steering Column Lock Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5382 K61 Sunroof Control Module (CF5) Component Connector End Views K61 Sunroof Control Module (CF5) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5383 K77 Remote Control Door Lock Receiver Component Connector End Views K77 Remote Control Door Lock Receiver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5384 K89 Immobilizer Control Module Component Connector End Views K89 Immobilizer Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5385 M6 Air Temperature Door Actuator Component Connector End Views M6 Air Temperature Door Actuator Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5386 M8 Blower Motor Component Connector End Views M8 Blower Motor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5387 M9 Brake Booster Pump Motor Component Connector End Views M9 Brake Booster Pump Motor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5388 M37 Mode Door Actuator Component Connector End Views M37 Mode Door Actuator Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5389 M40 Rear Compartment Lid Latch Component Connector End Views M40 Rear Compartment Lid Latch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5390 M46 Recirculation Door Motor Component Connector End Views M46 Recirculation Door Motor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5391 M74D Window Motor - Driver (AEC) Component Connector End Views M74D Window Motor - Driver (AEC) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5392 M74D Window Motor - Driver (AXG) Component Connector End Views M74D Window Motor - Driver (AXG) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5393 M74LR Window Motor - Left Rear Component Connector End Views M74LR Window Motor - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5394 M74P Window Motor - Passenger Component Connector End Views M74P Window Motor - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5395 M74RR Window Motor - Right Rear Component Connector End Views M74RR Window Motor - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5396 M75 Windshield Wiper Motor Component Connector End Views M75 Windshield Wiper Motor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5397 M932 Ignition Lock Cylinder Control Solenoid Actuator (MH8) Component Connector End Views M932 Ignition Lock Cylinder Control Solenoid Actuator (MH8) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5398 P2 Automatic Transmission Shift Lever Position Indicator Component Connector End Views P2 Automatic Transmission Shift Lever Position Indicator Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5399 P12 Horn Component Connector End Views P12 Horn Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5400 P14 Passenger Air Bag Disable Indicator Component Connector End Views P14 Passenger Air Bag Disable Indicator Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5401 P16 Instrument Cluster Component Connector End Views P16 Instrument Cluster Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5402 P17 Info Display Module (UAG or UFD) Component Connector End Views P17 Info Display Module (UAG or UFD) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5403 P17 Info Display Module (UDN) Component Connector End Views P17 Info Display Module (UDN) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5404 P19B Speaker - Center Instrument Panel Component Connector End Views P19B Speaker - Center Instrument Panel Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5405 P19AA Speaker - Right Subwoofer Component Connector End Views P19AA Speaker - Right Subwoofer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5406 P19G Speaker - Left Front Component Connector End Views P19G Speaker - Left Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5407 P19H Speaker - Left Front Tweeter (UQA) Component Connector End Views P19H Speaker - Left Front Tweeter (UQA) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5408 P19K Speaker - Left Rear Component Connector End Views P19K Speaker - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5409 P19N Speaker - Left Subwoofer Component Connector End Views P19N Speaker - Left Subwoofer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5410 P19U Speaker - Right Front Component Connector End Views P19U Speaker - Right Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5411 P19V Speaker - Right Front Tweeter (UQA) Component Connector End Views P19V Speaker - Right Front Tweeter (UQA) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5412 P19X Speaker - Right Rear Component Connector End Views P19X Speaker - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5413 Q13 Evaporative Emission Vent Solenoid Valve Component Connector End Views Q13 Evaporative Emission Vent Solenoid Valve Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5414 S3 Automatic Transmission Shift Lever (MH8) Component Connector End Views S3 Automatic Transmission Shift Lever (MH8) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5415 S13D Door Lock Switch - Driver Component Connector End Views S13D Door Lock Switch - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5416 S26 Hazard Lamps Switch Component Connector End Views S26 Hazard Lamps Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5417 S30 Headlamp Switch Component Connector End Views S30 Headlamp Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5418 S34 HVAC Controls Switch Assembly Component Connector End Views S34 HVAC Controls Switch Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5419 S52 Outside Rearview Mirror Switch Component Connector End Views S52 Outside Rearview Mirror Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5420 S70R Steering Wheel Controls Switch - Right Component Connector End Views S70R Steering Wheel Controls Switch - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5421 S72 Sunroof Switch (CF5) Component Connector End Views S72 Sunroof Switch (CF5) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5422 S78 Turn Signal/Multi-Function Switch Component Connector End Views S78 Turn Signal/Multi-Function Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5423 S79D Window Switch - Driver (AEC) Component Connector End Views S79D Window Switch - Driver (AEC) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5424 S79D Window Switch - Driver (AXG) Component Connector End Views S79D Window Switch - Driver (AXG) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5425 S79LR Window Switch - Left Rear Component Connector End Views S79LR Window Switch - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5426 S79P Window Switch - Passenger Component Connector End Views S79P Window Switch - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5427 S79RR Window Switch - Right Rear Component Connector End Views S79RR Window Switch - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5428 S80 Window Wiper/Washer Switch Component Connector End Views S80 Window Wiper/Washer Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5429 S88 Sunroof Tilt Switch (CF5) Component Connector End Views S88 Sunroof Tilt Switch (CF5) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5430 T11 Multimedia Interface Module (KTA) Component Connector End Views T11 Multimedia Interface Module (KTA) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5431 X80L Accessory Power Receptacle - Rear Console (KC7) Component Connector End Views X80L Accessory Power Receptacle - Rear Console (KC7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5432 X83 Auxiliary Audio Input Component Connector End Views X83 Auxiliary Audio Input Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5433 X84 Data Link Connector Component Connector End Views X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5434 X85 Steering Wheel Air Bag Coil X1 Component Connector End Views X85 Steering Wheel Air Bag Coil X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5435 X85 Steering Wheel Air Bag Coil X2 Component Connector End Views X85 Steering Wheel Air Bag Coil X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5436 X85 Steering Wheel Air Bag Coil X3 Component Connector End Views X85 Steering Wheel Air Bag Coil X3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5437 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5438 Multiple Junction Connector: Diagrams Connector End Views By Number X100 Inline Harness Connector End Views X100 Body Harness to Forward Lamp Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5439 X102 Inline Harness Connector End Views X102 Engine Cooling Harness to Forward Lamp Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5440 X104 Inline Harness Connector End Views X104 Engine Cooling Harness to Forward Lamp Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5441 X110 Inline Harness Connector End Views X110 Body Harness to Engine Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5442 X114 Inline Harness Connector End Views X114 Power Steering Harness to Forward Lamp Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5443 X200 Inline Harness Connector End Views X200 Instrument Panel Harness to Body Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5444 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5445 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5446 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5447 X205 Inline Harness Connector End Views X205 Instrument Panel Harness to Body Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5448 X210 Inline Harness Connector End Views X210 Headliner Harness to Body Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5449 X211 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5450 Inline Harness Connector End Views X211 Headliner Harness to Body Harness X212 Inline Harness Connector End Views X212 Instrument Panel Harness to HVAC Harness (C68) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5451 X300 Inline Harness Connector End Views X300 Console Harness to Instrument Panel Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5452 X310 Inline Harness Connector End Views X310 Body Harness and Driver Seat Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5453 X315 Inline Harness Connector End Views X315 Body Harness and Passenger Seat Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5454 X320 Inline Harness Connector End Views X320 Body Harness to Curtain Air Bag Jumper Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5455 X321 Inline Harness Connector End Views X321 Body Harness to Curtain Air Bag Jumper Harness X401 Inline Harness Connector End Views X401 Fuel Tank Harness to Body Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5456 X402 Inline Harness Connector End Views X402 Rear Object Sensor to Harness Body Harness (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5457 X410 Inline Harness Connector End Views X410 Left Tail Lamp Harness to Body Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5458 X411 Inline Harness Connector End Views X411 Right Tail Lamp Harness to Body Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5459 X500 - X599 Inline Harness Connector End Views X500 Driver Door Harness to Body Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5460 X600 - X699 Inline Harness Connector End Views X600 Passenger Door Harness to Body Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5461 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5462 X700 - X799 Inline Harness Connector End Views X700 Left Rear Door Harness to Body Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5463 X800 - X899 Inline Harness Connector End Views X800 Right Rear Door Harness to Body Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5464 X900 Inline Harness Connector End Views X900 Rear Compartment Lid Harness to Body Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5465 X920 Inline Harness Connector End Views X920 License Lamp Harness to Rear Compartment Lid Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 5466 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations/A - Z Index) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 5471 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Fuse/Application and ID) to locate the electrical center where the relay exists. Note: * Always note the orientation of the relay. * If equipped with a notch style relay; observe the location of the notch on the old relay to verify the new relay is installed with the notch in the same location. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 5472 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Accessory Relay > Component Information > Locations Accessory Relay: Locations Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Accessory Relay > Component Information > Locations > Page 5477 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations/A - Z Index) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 5482 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Fuse/Application and ID) to locate the electrical center where the relay exists. Note: * Always note the orientation of the relay. * If equipped with a notch style relay; observe the location of the notch on the old relay to verify the new relay is installed with the notch in the same location. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 5483 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery Relay Box: Application and ID Fuse Block - Battery Electrical Center Identification Views X50D Fuse Block - Battery Auxiliary Top View X50D Fuse Block - Battery Auxiliary Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5488 X50D Fuse Block - Battery Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5489 X50D Fuse Block - Battery Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5490 X50D Fuse Block - Battery X3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5491 X50D Fuse Block - Battery X4 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5492 X50D Fuse Block - Battery X6 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5493 Relay Box: Application and ID Fuse Block - Underhood Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5494 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5495 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5496 X50A Fuse Block - Underhood Bottom View X50A Fuse Block - Underhood Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5497 X50A Fuse Block - Underhood X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5498 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5499 X50A Fuse Block - Underhood X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5500 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5501 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5502 X50B Fuse Block - Underhood Auxiliary X8 X50B Fuse Block - Underhood Auxiliary X9 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5503 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5504 Relay Box: Application and ID Fuse Block - Instrument Panel Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5505 X51A Fuse Block - Instrument Panel (Fuses) Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5506 X51A Fuse Block - Instrument Panel (Relays) Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5507 X51A Fuse Block - Instrument Panel Bottom View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5508 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery Relay Box: Application and ID Fuse Block - Battery Electrical Center Identification Views X50D Fuse Block - Battery Auxiliary Top View X50D Fuse Block - Battery Auxiliary Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5513 X50D Fuse Block - Battery Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5514 X50D Fuse Block - Battery Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5515 X50D Fuse Block - Battery X3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5516 X50D Fuse Block - Battery X4 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5517 X50D Fuse Block - Battery X6 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5518 Relay Box: Application and ID Fuse Block - Underhood Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5519 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5520 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5521 X50A Fuse Block - Underhood Bottom View X50A Fuse Block - Underhood Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5522 X50A Fuse Block - Underhood X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5523 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5524 X50A Fuse Block - Underhood X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5525 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5526 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5527 X50B Fuse Block - Underhood Auxiliary X8 X50B Fuse Block - Underhood Auxiliary X9 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5528 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5529 Relay Box: Application and ID Fuse Block - Instrument Panel Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5530 X51A Fuse Block - Instrument Panel (Fuses) Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5531 X51A Fuse Block - Instrument Panel (Relays) Top View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5532 X51A Fuse Block - Instrument Panel Bottom View Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Battery > Page 5533 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 5542 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 5543 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 5544 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 5549 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 5555 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 5556 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 5557 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5562 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5563 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5564 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5565 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5566 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5567 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 5572 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5578 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5579 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5580 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5581 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5582 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 5583 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 5589 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 5590 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 5591 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 5592 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 5593 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 5594 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 5595 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications Alignment: Specifications Trim Height Specifications Trim Height Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications > Page 5598 Alignment: Specifications Wheel Alignment Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber Description Alignment: Description and Operation Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber Description > Page 5601 Alignment: Description and Operation Toe Description Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber Description > Page 5602 Alignment: Description and Operation Thrust Angles Description Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. If the thrust angle is not set properly the vehicle may "dog track", the steering wheel may not be centered or it could be perceived as a bent axle. Thrust angle can be checked during a wheel alignment. Positive thrust angle means the thrust line is pointing to the right hand side (RHS) of the vehicle. Negative thrust angle means the thrust line is pointing to the left hand side (LHS) of the vehicle. If the thrust angle is out of specification, moving the axle to body relationship will change the thrust angle reading. If the vehicle is out in the Positive (+) direction-moving the RHS forward and/or LHS rearward will move the thrust angle towards zero degrees. If the vehicle is out in the Negative (-) direction-moving the RHS rearward and/or LHS forward will move the thrust angle towards zero degrees. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber Description > Page 5603 Alignment: Description and Operation Lead/Pull Description Lead/Pull Description At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Note: Vehicles will tend to lead/pull in the direction of the road slope as part of normal operation. Lead/pull is usually caused by the following factors: * Road slope * Variability in tire construction * Wheel alignment (front cross caster and camber) * Unbalanced steering gear * Electronic power steering (EPS) steering position and torque sensors not calibrated correctly, if equipped Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber Description > Page 5604 Alignment: Description and Operation Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Thrust Angles Description Thrust Angles Description Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber Description > Page 5605 The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. If the thrust angle is not set properly the vehicle may "dog track", the steering wheel may not be centered or it could be perceived as a bent axle. Thrust angle can be checked during a wheel alignment. Positive thrust angle means the thrust line is pointing to the right hand side (RHS) of the vehicle. Negative thrust angle means the thrust line is pointing to the left hand side (LHS) of the vehicle. If the thrust angle is out of specification, moving the axle to body relationship will change the thrust angle reading. If the vehicle is out in the Positive (+) direction-moving the RHS forward and/or LHS rearward will move the thrust angle towards zero degrees. If the vehicle is out in the Negative (-) direction-moving the RHS rearward and/or LHS forward will move the thrust angle towards zero degrees. Lead/Pull Description Lead/Pull Description At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Note: Vehicles will tend to lead/pull in the direction of the road slope as part of normal operation. Lead/pull is usually caused by the following factors: * Road slope * Variability in tire construction * Wheel alignment (front cross caster and camber) * Unbalanced steering gear * Electronic power steering (EPS) steering position and torque sensors not calibrated correctly, if equipped Torque Steer Description Torque Steer Description Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber Description > Page 5606 A vehicle pulls or leads in one direction during hard acceleration. A vehicle pulls or leads in the other direction during deceleration. The following factors may cause torque steer to be more apparent on a particular vehicle: * A slightly smaller diameter tire on the right front increases a right torque lead. Inspect the front tires for differences in the brand, the construction, or the size. If the tires appear to be similar, change the front tires from side-to-side and retest the vehicle. Tire and wheel assemblies have the most significant effect on torque steer correction. * A large difference in the right and left front tire pressure * Left-to-right differences in the front view axle angle may cause significant steering pull in a vehicle. The pull will be to the side with the most downward sloping axle from the differential to the wheels. Axles typically slope downward from the differential. The slope of the transaxle pan to level ground may be used as an indication of bias axle angles. The side with the higher transaxle pan (shown on the left side of the illustration) has the most downward sloping axle angle. Memory Steer Description Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 5607 Alignment: Testing and Inspection Trim Height Inspection Trim Height Measurement Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause the vehicle to bottom out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: * Set the tire pressure to the specifications shown on the certification label. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Note: One U.S. gallon of gasoline weighs approximately 6.5 lbs. One liter of gasoline weighs approximately 0.78 kg. * Check the fuel level. Add additional weight if necessary to simulate a full tank. * Make sure the passenger and rear compartments are empty, except to the spare tire. * Make sure the vehicle is on a flat and level surface, such as an alignment rack. * Check that all the vehicle doors are securely closed. * Check that the vehicle hood and rear deck lid are securely closed. * Make sure the vehicle is free of ice, snow and mud accumulation. * Check for installed after market accessories or modifications that could affect trim height measurement: - Larger or smaller than production wheels and tires. - Lifting or lowering kits - Wheel opening flares or ground affects Measuring the P and R Dimension Measurement Definitions P Height: The vertical distance from the ground to the top of the wheel opening through the centerline of the front wheel. R Height: The vertical distance from the ground to the top of the wheel opening through the centerline of the rear wheel. Use the following procedures to measure the P and R dimensions: Note: * Measure from the center of the wheel well opening to the ground. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 5608 * The left and right P and R height differences should be no more than 10 mm (0.39 in). 1. Push the front bumper down a minimum of 25 mm (1 in) , and release. Perform this step three times. 2. Measure and record the trim height per the "Measurement Definitions" above. 3. Lift the bumper up a minimum of 25 mm (1 in) , and release. Perform this step three times. 4. Measure and record the trim height per the "Measurement Definitions" above. 5. The true P height measurement is the average of the measurements taken in step 2 and 4. Refer to Trim Height Specifications (See: Suspension/Specifications/Mechanical Specifications/Trim Height Specifications). 6. Repeat the above steps at the rear of the vehicle for the R heights. 7. If the P and R heights are outside of the specifications, measure the Z and D heights. Measuring the Z Dimension Measurement Definitions The Z Height: The vertical distance from the cradle side rail bottom surface (2) accessed through hole in the engine shield to the center of the ball joint cup (1). Use the following procedures to measure the Z dimensions: Note: The left and right Z height differences should be no more than 10 mm (0.39 in). 1. Push the front bumper down a minimum of 25 mm (1 in). Perform this step three times. 2. Measure and record the trim height per the "Measurement Definitions" above. 3. Lift the front bumper a minimum of 25 mm (1 in). Perform this step three times. 4. Measure and record the trim height per the "Measurement Definitions" above. 5. The true Z height dimension is the average of the measurements taken in steps 2 and 4. Refer to Trim Height Specifications (See: Suspension/Specifications/Mechanical Specifications/Trim Height Specifications). 6. If these measurements are out of specifications, inspect for the following conditions: * Worn or damaged suspension components * Collision damage D Height Measurement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 5609 Measurement Definitions The D Height: The vertical distance from the bottom surface of the body side rail (1) to the center of the lower shock attaching bolt head (2). Use the following procedure to check the D dimension: Note: The left and right D height difference should be no more than 10 mm (0.39 in). 1. Push the rear bumper down a minimum of 25 mm (1 in). Perform this step three times. 2. Measure and record the trim height per the "Measurement Definitions" above. 3. Lift the rear bumper up a minimum of 25 mm (1 in) , and release. Perform this step three times. 4. Measure and record the trim height per the "Measurement Definitions" above. 5. The true D height is the average of the measurements taken in steps 2 and 4. Refer to Trim Height Specifications (See: Suspension/Specifications/Mechanical Specifications/Trim Height Specifications). 6. If these measurements are out of specifications, inspect for the following conditions: * Worn or damaged suspension components * Collision damage Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment Measurement Alignment: Service and Repair Wheel Alignment Measurement Wheel Alignment Measurement Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Radial Tire Lead/Pull Correction) in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections in order to ensure correct alignment readings: * Inspect for visible damage to the suspension components and replace as necessary. * Inspect the tires for the proper inflation and irregular tire wear. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label) and Tire Diagnosis - Irregular or Premature Wear (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Tire Diagnosis - Irregular or Premature Wear). * Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications (See: Body and Frame/Testing and Inspection/Vibration Diagnosis and Correction/Specifications). * Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings Diagnosis (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Wheel Bearings Diagnosis). * Inspect the ball joints for looseness or wear. * Inspect the tie rod ends for looseness or wear. * Inspect the control arms and stabilizer shaft for looseness or wear. * Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications (See: Steering/Specifications). * Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Suspension Strut and Shock Absorber Testing - On Vehicle (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Suspension Strut and Shock Absorber Testing - On Vehicle). * Inspect the vehicle trim height. Refer to Trim Height Inspection (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection). * Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. * Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. Note: * Record the "Before" and "After" alignment measurements. * When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear toe adjustment first in order to obtain proper front alignment angles. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 5612 Alignment: Service and Repair Front Camber Adjustment Front Camber Adjustment 1. Before performing any adjustment affecting the wheel alignment, refer to Wheel Alignment Measurement (See: Wheel Alignment Measurement). 2. Loosen both strut to knuckle nuts just enough to allow for movement. Note: If there is no adjustment for the camber, proceed to step 4. 3. Adjust the camber to specification by moving the top of the wheel in or out. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). 4. Remove the strut assembly from the vehicle. Refer to Strut Assembly Replacement (See: Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension/Strut Assembly Replacement). 5. Install the strut assembly in a soft jawed vise. Note: The inner hole should NOT be enlarged beyond that of the outer hole. 6. Using the appropriate tool, enlarge the inner hole (1) to match the outer hole (2). 7. Install the strut assembly. Refer to Strut Assembly Replacement (See: Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension/Strut Assembly Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 5613 Note: If there is no adjustment for the camber, proceed to step 4. 8. Adjust the camber to specification by moving the top of the wheel in or out. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 5614 Alignment: Service and Repair Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment 1. Ensure that the steering wheel is set in a straight ahead position. 2. Loosen the tie rod jam nut (1). 3. Adjust the toe to specification by turning the inner tie rod (2). Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the tie rod jam nut (1) to 60 Nm (44 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Wheels/Vehicle Underbody Component Views Front Frame and Underbody Components (NJ1) 1 - X1 Power Steering Control Module X1 2 - X2 Power Steering Control Module X2 3 - K43 Power Steering Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 5620 Steering Control Module: Service and Repair Power Steering Control Module Calibration Steering Angle Sensor Centering and Software Endstop Learning Warning An inaccurate or not centered steering angle sensor could limit the operation of the electric power steering (EPS) and result in personal injury. Centering of the steering angle sensor and software endstop learning might be required after certain service procedures are performed. Some of these procedures are as follows: * Steering angle sensor replacement * Steering gear replacement * Power steering assist motor replacement * Steering column replacement * Steering linkage inner tie rod replacement * Steering linkage outer tie rod replacement Note: It is necessary to perform the steering angle sensor centering before the software endstop learning. Steering Angle Sensor Centering For the centering procedure of the external steering angle sensor (electronic stability program) refer to Steering Angle Sensor Centering (See: Sensors and Switches - Steering and Suspension/Sensors and Switches - Steering/Steering Angle Sensor/Service and Repair/Procedures). The centering procedure of the internal steering angle sensor (w/o electronic stability program) can be completed with the following steps: Conditions: Front axle measured and set, engine running, vehicle speed 0 km/h (0 MPH), internal steering angle sensor is activated. 1. Using the steering wheel, align the front wheels in the center forward position. 2. Using a scan tool, perform the Configuration/Reset Functions, Steering Wheel Angle Sensor Centering procedure. 3. Steer from the center position slowly 90° to the left. 4. Steer slowly back to the center position and then slowly 90° to the right. 5. Steer slowly back to the center position. 6. Perform the steering movements again. 7. Centering procedure is completed. Software Endstop Learning The software endstop learning procedure can be completed with the following steps: Conditions: Front axle measured and set, vehicle speed 0 km/h (0 MPH), internal steering angle sensor is calibrated or external steering angle sensor sends a valid CAN signal. 1. Using a scan tool, perform the Configuration/Reset Functions, Power Steering Softstops Reset procedure and follow the on-screen instructions. 2. Using a scan tool, perform the Configuration/Reset Functions, Power Steering Softstops Learn procedure and follow the on-screen instructions. 3. Software endstop learning procedure is completed. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Procedures Steering Angle Sensor: Procedures Steering Angle Sensor Centering The external column mounted steering angle sensor does not require a centering often. Centering of the steering angle sensor might be required after certain service procedures are performed. Some of these procedures are as follows: * Electronic brake control module (EBCM) replacement * Steering angle sensor replacement * Steering gear replacement * Steering column replacement * Collision or other physical damage The external column mounted steering angle sensor centering procedure can be completed with a scan tool using the following steps: 1. Using the steering wheel, align the front wheels forward. 2. Apply the parking brake, or set the transmission in the P position. 3. Install the scan tool to the data link connector. 4. Ignition ON, engine OFF 5. Select Steering Wheel Angle Sensor Reset in the Steering Wheel Angle Sensor Module Configuration/Reset Functions list. 6. Follow the scan tool directions to complete the learn procedure. 7. Select Steering Wheel Angle Sensor Learn in the Steering Wheel Angle Sensor Module Configuration/Reset Functions list. 8. Follow the scan tool directions to complete the learn procedure. 9. Select Steering Wheel Angle Sensor Learn in the EBCM Configuration/Reset Functions list. 10. Follow the scan tool directions to complete the learn procedure. 11. Clear any DTCs that may be set. 12. If equipped with electric power steering (EPS), perform the Software Endstop Learning. Refer to Power Steering Control Module Calibration ( See: Relays and Modules - Steering and Suspension/Relays and Modules - Steering/Steering Control Module/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Procedures > Page 5633 Steering Angle Sensor: Removal and Replacement Steering Angle Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Procedures Steering Angle Sensor: Procedures Steering Angle Sensor Centering The external column mounted steering angle sensor does not require a centering often. Centering of the steering angle sensor might be required after certain service procedures are performed. Some of these procedures are as follows: * Electronic brake control module (EBCM) replacement * Steering angle sensor replacement * Steering gear replacement * Steering column replacement * Collision or other physical damage The external column mounted steering angle sensor centering procedure can be completed with a scan tool using the following steps: 1. Using the steering wheel, align the front wheels forward. 2. Apply the parking brake, or set the transmission in the P position. 3. Install the scan tool to the data link connector. 4. Ignition ON, engine OFF 5. Select Steering Wheel Angle Sensor Reset in the Steering Wheel Angle Sensor Module Configuration/Reset Functions list. 6. Follow the scan tool directions to complete the learn procedure. 7. Select Steering Wheel Angle Sensor Learn in the Steering Wheel Angle Sensor Module Configuration/Reset Functions list. 8. Follow the scan tool directions to complete the learn procedure. 9. Select Steering Wheel Angle Sensor Learn in the EBCM Configuration/Reset Functions list. 10. Follow the scan tool directions to complete the learn procedure. 11. Clear any DTCs that may be set. 12. If equipped with electric power steering (EPS), perform the Software Endstop Learning. Refer to Power Steering Control Module Calibration ( See: Relays and Modules - Steering and Suspension/Relays and Modules - Steering/Steering Control Module/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Procedures > Page 5640 Steering Angle Sensor: Removal and Replacement Steering Angle Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 5646 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: If any of the following tire pressure sensor components are found to be damage, replace the damaged components. 4. Remove the tire pressure sensor indicator cap and deflate the tire. 5. Remove tire pressure sensor indicator nut (4). Note: When removing the tire pressure sensor, DO NOT re-use the seal, replace with new. 6. Remove the tire pressure sensor seal (3), the washer (2) and the tire pressure sensor (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 5647 1. Clean the area around the mounting point for the tire pressure sensor. 2. Install the washer (2) and the seal (3) on the tire pressure sensor (1). 3. Install the tire pressure sensor (1) on the wheel. 4. Start the nut (4) by hand. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: When installing the tire pressure sensor and the nut, position the tire pressure sensor so that it is parallel to the inside wheel surface while torquing. 5. Install the nut (2) on the tire pressure sensor (1). Tighten the nut (2) to 7 Nm (62 lb in). 6. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Wheels and Tires/Tires/Service and Repair/Removal and Replacement). 7. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 5648 8. Lower the vehicle. 9. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Wheels and Tires/Tire Monitoring System/Service and Repair/Tire Pressure Indicator Sensor Learn). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Steering Knuckle Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Page 5657 Power Steering Fluid: Service Precautions Air in the Power Steering System Caution Caution: If the power steering system has been serviced, an accurate fluid level reading cannot be obtained unless air is bled from the steering system. The air in the fluid may cause pump cavitation noise and may cause pump damage over a period of time. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service Precautions Power Steering Line/Hose: Service Precautions Power Steering Hose Disconnected Caution Caution: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected. When disconnected, plug or cap all openings of components. Failure to do so could result in contamination or loss of power steering fluid and damage to the system. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Service and Repair Power Steering Motor: Service and Repair Power Steering Assist Motor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Service and Repair > Page 5664 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Wheels/Vehicle Underbody Component Views Front Frame and Underbody Components (NJ1) 1 - X1 Power Steering Control Module X1 2 - X2 Power Steering Control Module X2 3 - K43 Power Steering Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 5668 Steering Control Module: Service and Repair Power Steering Control Module Calibration Steering Angle Sensor Centering and Software Endstop Learning Warning An inaccurate or not centered steering angle sensor could limit the operation of the electric power steering (EPS) and result in personal injury. Centering of the steering angle sensor and software endstop learning might be required after certain service procedures are performed. Some of these procedures are as follows: * Steering angle sensor replacement * Steering gear replacement * Power steering assist motor replacement * Steering column replacement * Steering linkage inner tie rod replacement * Steering linkage outer tie rod replacement Note: It is necessary to perform the steering angle sensor centering before the software endstop learning. Steering Angle Sensor Centering For the centering procedure of the external steering angle sensor (electronic stability program) refer to Steering Angle Sensor Centering (See: Sensors and Switches - Steering/Steering Angle Sensor/Service and Repair/Procedures). The centering procedure of the internal steering angle sensor (w/o electronic stability program) can be completed with the following steps: Conditions: Front axle measured and set, engine running, vehicle speed 0 km/h (0 MPH), internal steering angle sensor is activated. 1. Using the steering wheel, align the front wheels in the center forward position. 2. Using a scan tool, perform the Configuration/Reset Functions, Steering Wheel Angle Sensor Centering procedure. 3. Steer from the center position slowly 90° to the left. 4. Steer slowly back to the center position and then slowly 90° to the right. 5. Steer slowly back to the center position. 6. Perform the steering movements again. 7. Centering procedure is completed. Software Endstop Learning The software endstop learning procedure can be completed with the following steps: Conditions: Front axle measured and set, vehicle speed 0 km/h (0 MPH), internal steering angle sensor is calibrated or external steering angle sensor sends a valid CAN signal. 1. Using a scan tool, perform the Configuration/Reset Functions, Power Steering Softstops Reset procedure and follow the on-screen instructions. 2. Using a scan tool, perform the Configuration/Reset Functions, Power Steering Softstops Learn procedure and follow the on-screen instructions. 3. Software endstop learning procedure is completed. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Wheels/Vehicle Underbody Component Views Front Frame and Underbody Components (NJ1) 1 - X1 Power Steering Control Module X1 2 - X2 Power Steering Control Module X2 3 - K43 Power Steering Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 5673 Steering Control Module: Service and Repair Power Steering Control Module Calibration Steering Angle Sensor Centering and Software Endstop Learning Warning An inaccurate or not centered steering angle sensor could limit the operation of the electric power steering (EPS) and result in personal injury. Centering of the steering angle sensor and software endstop learning might be required after certain service procedures are performed. Some of these procedures are as follows: * Steering angle sensor replacement * Steering gear replacement * Power steering assist motor replacement * Steering column replacement * Steering linkage inner tie rod replacement * Steering linkage outer tie rod replacement Note: It is necessary to perform the steering angle sensor centering before the software endstop learning. Steering Angle Sensor Centering For the centering procedure of the external steering angle sensor (electronic stability program) refer to Steering Angle Sensor Centering (See: Sensors and Switches - Steering/Steering Angle Sensor/Service and Repair/Procedures). The centering procedure of the internal steering angle sensor (w/o electronic stability program) can be completed with the following steps: Conditions: Front axle measured and set, engine running, vehicle speed 0 km/h (0 MPH), internal steering angle sensor is activated. 1. Using the steering wheel, align the front wheels in the center forward position. 2. Using a scan tool, perform the Configuration/Reset Functions, Steering Wheel Angle Sensor Centering procedure. 3. Steer from the center position slowly 90° to the left. 4. Steer slowly back to the center position and then slowly 90° to the right. 5. Steer slowly back to the center position. 6. Perform the steering movements again. 7. Centering procedure is completed. Software Endstop Learning The software endstop learning procedure can be completed with the following steps: Conditions: Front axle measured and set, vehicle speed 0 km/h (0 MPH), internal steering angle sensor is calibrated or external steering angle sensor sends a valid CAN signal. 1. Using a scan tool, perform the Configuration/Reset Functions, Power Steering Softstops Reset procedure and follow the on-screen instructions. 2. Using a scan tool, perform the Configuration/Reset Functions, Power Steering Softstops Learn procedure and follow the on-screen instructions. 3. Software endstop learning procedure is completed. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Procedures Steering Angle Sensor: Procedures Steering Angle Sensor Centering The external column mounted steering angle sensor does not require a centering often. Centering of the steering angle sensor might be required after certain service procedures are performed. Some of these procedures are as follows: * Electronic brake control module (EBCM) replacement * Steering angle sensor replacement * Steering gear replacement * Steering column replacement * Collision or other physical damage The external column mounted steering angle sensor centering procedure can be completed with a scan tool using the following steps: 1. Using the steering wheel, align the front wheels forward. 2. Apply the parking brake, or set the transmission in the P position. 3. Install the scan tool to the data link connector. 4. Ignition ON, engine OFF 5. Select Steering Wheel Angle Sensor Reset in the Steering Wheel Angle Sensor Module Configuration/Reset Functions list. 6. Follow the scan tool directions to complete the learn procedure. 7. Select Steering Wheel Angle Sensor Learn in the Steering Wheel Angle Sensor Module Configuration/Reset Functions list. 8. Follow the scan tool directions to complete the learn procedure. 9. Select Steering Wheel Angle Sensor Learn in the EBCM Configuration/Reset Functions list. 10. Follow the scan tool directions to complete the learn procedure. 11. Clear any DTCs that may be set. 12. If equipped with electric power steering (EPS), perform the Software Endstop Learning. Refer to Power Steering Control Module Calibration ( See: Power Steering/Steering Control Module/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Procedures > Page 5680 Steering Angle Sensor: Removal and Replacement Steering Angle Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Procedures Steering Angle Sensor: Procedures Steering Angle Sensor Centering The external column mounted steering angle sensor does not require a centering often. Centering of the steering angle sensor might be required after certain service procedures are performed. Some of these procedures are as follows: * Electronic brake control module (EBCM) replacement * Steering angle sensor replacement * Steering gear replacement * Steering column replacement * Collision or other physical damage The external column mounted steering angle sensor centering procedure can be completed with a scan tool using the following steps: 1. Using the steering wheel, align the front wheels forward. 2. Apply the parking brake, or set the transmission in the P position. 3. Install the scan tool to the data link connector. 4. Ignition ON, engine OFF 5. Select Steering Wheel Angle Sensor Reset in the Steering Wheel Angle Sensor Module Configuration/Reset Functions list. 6. Follow the scan tool directions to complete the learn procedure. 7. Select Steering Wheel Angle Sensor Learn in the Steering Wheel Angle Sensor Module Configuration/Reset Functions list. 8. Follow the scan tool directions to complete the learn procedure. 9. Select Steering Wheel Angle Sensor Learn in the EBCM Configuration/Reset Functions list. 10. Follow the scan tool directions to complete the learn procedure. 11. Clear any DTCs that may be set. 12. If equipped with electric power steering (EPS), perform the Software Endstop Learning. Refer to Power Steering Control Module Calibration ( See: Power Steering/Steering Control Module/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Procedures > Page 5686 Steering Angle Sensor: Removal and Replacement Steering Angle Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Restraint Systems/Air Bag Systems/Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 5691 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Restraint Systems/Air Bag Systems/Diagrams/Electrical Diagrams ) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Technical Service Bulletins > Recalls: > 11094 > Apr > 11 > Recall - Steering Wheel Fastener Inspection Technical Service Bulletin # 11094 Date: 110405 Recall - Steering Wheel Fastener Inspection SAFETY Bulletin No.: 11094 Date: April 05, 2011 Subject: 11094 - Steering Wheel Fastener Inspection Models: 2011 Chevrolet Cruze The vehicles involved in this safety recall were previously included in PIE0158. PIE0158 will be closed and all vehicles that did not have the inspection performed will be transferred to this safety recall. Condition General Motors has decided that a defect, which relates to motor vehicle safety, may exist in certain 2011 model year Chevrolet Cruze vehicles. In the unlikely event that an assembly plant repair procedure results in an improperly fastened steering wheel, the steering wheel may come loose from the steering column. If this were to happen while the vehicle was moving, the driver could lose the ability to steer the vehicle, potentially leading to a crash. Correction Dealers are to inspect and ensure that the steering wheel is assembled properly. Vehicles Involved Involved are certain 2011 model year Chevrolet Cruze vehicles. Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. * NO vehicles are expected to require a steering wheel bolt. Service Procedure 1. Start the vehicle and rotate steering wheel to position the access holes above the steering column. Place the ignition in the OFF position. 2. Disconnect the negative battery cable to disable the supplemental inflatable restraint (SIR) system. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Remove the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Technical Service Bulletins > Recalls: > 11094 > Apr > 11 > Recall - Steering Wheel Fastener Inspection > Page 5700 4. Insert suitable tools to the openings (2) on both sides of the steering wheel (1). 5. Release the springs in direction of the arrows. 6. Remove Driver Airbag Module (DAB). DO NOT disconnect the two yellow electrical connectors. 7. Inspect the hub area of the steering wheel for the attachment bolt (1). - If the attachment bolt (1) is NOT present, install a new attachment bolt, P/N 11610164. Apply Medium Strength Threadlocker - Blue Loctite(R) 242 (or equivalent) to the attachment bolt threads and tighten the bolt to 30 Nm (23 lb ft). Proceed to Step 8 after installing the new attachment bolt. - If the attachment bolt is present, proceed to Step 8. 8. Reinstall DAB by aligning the two attachment pins to the steering wheel square holes. 9. Push the DAB (1) firmly into the steering column in order the engage the fasteners. Ensure yellow connector wires are routed properly and are not pinched. 10. Install the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement in SI. 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Courtesy Transportation Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Technical Service Bulletins > Recalls: > 11094 > Apr > 11 > Recall - Steering Wheel Fastener Inspection > Page 5701 The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). Dealer Recall Responsibility - For US (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter April 2011 Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Technical Service Bulletins > Recalls: > 11094 > Apr > 11 > Recall - Steering Wheel Fastener Inspection > Page 5702 General Motors has decided that a defect, which relates to motor vehicle safety, may exist in certain 2011 Chevrolet Cruze vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in safety recall 11094. - Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? In the unlikely event that an assembly plant repair procedure was performed on your vehicle, and it resulted in an improperly fastened steering wheel, the steering wheel may come loose from the steering column. If this were to happen while the vehicle was moving, you could lose the ability to steer the vehicle, potentially leading to a crash. What will we do? Your GM dealer will inspect to ensure that the steering wheel is assembled properly. This service will be performed for you at no charge. Because of service scheduling requirements, it is likely that your dealer will need your vehicle longer than the actual inspection time of approximately 20 minutes. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment as soon as possible. If you are concerned about driving your vehicle to your dealer for inspection, you can contact the dealership and they will assist you in getting the vehicle to the dealership. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Jim Moloney General Director, Customer and Relationship Services 11094 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Column Cover: > 05-08-46-004C > Dec > 10 > Recalls for Steering Column Cover: > 11094 > Apr > 11 > Recall - Steering Wheel Fastener Inspection Technical Service Bulletin # 11094 Date: 110405 Recall - Steering Wheel Fastener Inspection SAFETY Bulletin No.: 11094 Date: April 05, 2011 Subject: 11094 - Steering Wheel Fastener Inspection Models: 2011 Chevrolet Cruze The vehicles involved in this safety recall were previously included in PIE0158. PIE0158 will be closed and all vehicles that did not have the inspection performed will be transferred to this safety recall. Condition General Motors has decided that a defect, which relates to motor vehicle safety, may exist in certain 2011 model year Chevrolet Cruze vehicles. In the unlikely event that an assembly plant repair procedure results in an improperly fastened steering wheel, the steering wheel may come loose from the steering column. If this were to happen while the vehicle was moving, the driver could lose the ability to steer the vehicle, potentially leading to a crash. Correction Dealers are to inspect and ensure that the steering wheel is assembled properly. Vehicles Involved Involved are certain 2011 model year Chevrolet Cruze vehicles. Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. * NO vehicles are expected to require a steering wheel bolt. Service Procedure 1. Start the vehicle and rotate steering wheel to position the access holes above the steering column. Place the ignition in the OFF position. 2. Disconnect the negative battery cable to disable the supplemental inflatable restraint (SIR) system. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Remove the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Column Cover: > 05-08-46-004C > Dec > 10 > Recalls for Steering Column Cover: > 11094 > Apr > 11 > Recall - Steering Wheel Fastener Inspection > Page 5712 4. Insert suitable tools to the openings (2) on both sides of the steering wheel (1). 5. Release the springs in direction of the arrows. 6. Remove Driver Airbag Module (DAB). DO NOT disconnect the two yellow electrical connectors. 7. Inspect the hub area of the steering wheel for the attachment bolt (1). - If the attachment bolt (1) is NOT present, install a new attachment bolt, P/N 11610164. Apply Medium Strength Threadlocker - Blue Loctite(R) 242 (or equivalent) to the attachment bolt threads and tighten the bolt to 30 Nm (23 lb ft). Proceed to Step 8 after installing the new attachment bolt. - If the attachment bolt is present, proceed to Step 8. 8. Reinstall DAB by aligning the two attachment pins to the steering wheel square holes. 9. Push the DAB (1) firmly into the steering column in order the engage the fasteners. Ensure yellow connector wires are routed properly and are not pinched. 10. Install the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement in SI. 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Courtesy Transportation Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Column Cover: > 05-08-46-004C > Dec > 10 > Recalls for Steering Column Cover: > 11094 > Apr > 11 > Recall - Steering Wheel Fastener Inspection > Page 5713 The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). Dealer Recall Responsibility - For US (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter April 2011 Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Column Cover: > 05-08-46-004C > Dec > 10 > Recalls for Steering Column Cover: > 11094 > Apr > 11 > Recall - Steering Wheel Fastener Inspection > Page 5714 General Motors has decided that a defect, which relates to motor vehicle safety, may exist in certain 2011 Chevrolet Cruze vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in safety recall 11094. - Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? In the unlikely event that an assembly plant repair procedure was performed on your vehicle, and it resulted in an improperly fastened steering wheel, the steering wheel may come loose from the steering column. If this were to happen while the vehicle was moving, you could lose the ability to steer the vehicle, potentially leading to a crash. What will we do? Your GM dealer will inspect to ensure that the steering wheel is assembled properly. This service will be performed for you at no charge. Because of service scheduling requirements, it is likely that your dealer will need your vehicle longer than the actual inspection time of approximately 20 minutes. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment as soon as possible. If you are concerned about driving your vehicle to your dealer for inspection, you can contact the dealership and they will assist you in getting the vehicle to the dealership. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Jim Moloney General Director, Customer and Relationship Services 11094 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Column Cover: > Page 5715 Parking Assist Control Module: Diagrams Component Connector End Views K41 Parking Assist Control Module X1 (UD7) K41 Parking Assist Control Module X2 (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Column Cover: > Page 5716 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Component Information > Locations Parking Assist Control Module: Locations Luggage Compartment/Rear of Vehicle Component Views Left Side of the Luggage Compartment Components 1 - X2 Parking Assist Control Module X2 2 - X1 Parking Assist Control Module X1 3 - K41 Parking Assist Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Component Information > Locations > Page 5720 Parking Assist Control Module: Diagrams Component Connector End Views K41 Parking Assist Control Module X1 (UD7) K41 Parking Assist Control Module X2 (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Component Information > Locations > Page 5721 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Component Information > Locations > Page 5722 Parking Assist Control Module: Service and Repair Rear Object Alarm Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Global Positioning System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 5730 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Global Positioning System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 5736 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Other Service Bulletins for Global Positioning System: > 11094 > Apr > 11 > Recall - Steering Wheel Fastener Inspection Technical Service Bulletin # 11094 Date: 110405 Recall - Steering Wheel Fastener Inspection SAFETY Bulletin No.: 11094 Date: April 05, 2011 Subject: 11094 - Steering Wheel Fastener Inspection Models: 2011 Chevrolet Cruze The vehicles involved in this safety recall were previously included in PIE0158. PIE0158 will be closed and all vehicles that did not have the inspection performed will be transferred to this safety recall. Condition General Motors has decided that a defect, which relates to motor vehicle safety, may exist in certain 2011 model year Chevrolet Cruze vehicles. In the unlikely event that an assembly plant repair procedure results in an improperly fastened steering wheel, the steering wheel may come loose from the steering column. If this were to happen while the vehicle was moving, the driver could lose the ability to steer the vehicle, potentially leading to a crash. Correction Dealers are to inspect and ensure that the steering wheel is assembled properly. Vehicles Involved Involved are certain 2011 model year Chevrolet Cruze vehicles. Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. * NO vehicles are expected to require a steering wheel bolt. Service Procedure 1. Start the vehicle and rotate steering wheel to position the access holes above the steering column. Place the ignition in the OFF position. 2. Disconnect the negative battery cable to disable the supplemental inflatable restraint (SIR) system. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Remove the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Other Service Bulletins for Global Positioning System: > 11094 > Apr > 11 > Recall - Steering Wheel Fastener Inspection > Page 5742 4. Insert suitable tools to the openings (2) on both sides of the steering wheel (1). 5. Release the springs in direction of the arrows. 6. Remove Driver Airbag Module (DAB). DO NOT disconnect the two yellow electrical connectors. 7. Inspect the hub area of the steering wheel for the attachment bolt (1). - If the attachment bolt (1) is NOT present, install a new attachment bolt, P/N 11610164. Apply Medium Strength Threadlocker - Blue Loctite(R) 242 (or equivalent) to the attachment bolt threads and tighten the bolt to 30 Nm (23 lb ft). Proceed to Step 8 after installing the new attachment bolt. - If the attachment bolt is present, proceed to Step 8. 8. Reinstall DAB by aligning the two attachment pins to the steering wheel square holes. 9. Push the DAB (1) firmly into the steering column in order the engage the fasteners. Ensure yellow connector wires are routed properly and are not pinched. 10. Install the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement in SI. 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Courtesy Transportation Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Other Service Bulletins for Global Positioning System: > 11094 > Apr > 11 > Recall - Steering Wheel Fastener Inspection > Page 5743 The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). Dealer Recall Responsibility - For US (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter April 2011 Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Other Service Bulletins for Global Positioning System: > 11094 > Apr > 11 > Recall - Steering Wheel Fastener Inspection > Page 5744 General Motors has decided that a defect, which relates to motor vehicle safety, may exist in certain 2011 Chevrolet Cruze vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in safety recall 11094. - Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? In the unlikely event that an assembly plant repair procedure was performed on your vehicle, and it resulted in an improperly fastened steering wheel, the steering wheel may come loose from the steering column. If this were to happen while the vehicle was moving, you could lose the ability to steer the vehicle, potentially leading to a crash. What will we do? Your GM dealer will inspect to ensure that the steering wheel is assembled properly. This service will be performed for you at no charge. Because of service scheduling requirements, it is likely that your dealer will need your vehicle longer than the actual inspection time of approximately 20 minutes. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment as soon as possible. If you are concerned about driving your vehicle to your dealer for inspection, you can contact the dealership and they will assist you in getting the vehicle to the dealership. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Jim Moloney General Director, Customer and Relationship Services 11094 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Diagrams Steering Column Lock: Diagrams Component Connector End Views K60 Steering Column Lock Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot Replacement Steering Gear: Service and Repair Steering Gear Boot Replacement Steering Gear Boot Replacement Special Tools CH-22610 - Keystone Clamp Pliers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the steering linkage outer tie rod. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). 3. Remove the steering linkage inner tie rod nut. 4. Remove the outer boot clamp (1). Discard the clamp. 5. Cut the inner boot clamp (3). Discard the clamp. 6. Remove the steering gear boot (2). 7. Clean the steering linkage inner tie rod and the steering gear boot contact area of any lubricant or debris. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot Replacement > Page 5752 Note: The steering linkage inner tie rod and the steering gear boot must be free of moisture and debris. 1. Apply approximately 3/4 of the supplied lubricant packet to the inside of the small end of the steering gear boot (2). Apply the remainder of the lubricant to the steering linkage inner tie rod where the small end of the steering gear boot touches the inner tie rod. Note: Ensure the larger end of the steering gear boot is firmly seated in the correct location on the steering gear. 2. Install the steering gear boot with the NEW inner boot clamp (3) loosely attached. 3. Use the CH-22610 - pliers in order to install the NEW inner boot clamp (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot Replacement > Page 5753 Note: Ensure the small end of the steering gear boot is firmly seated in the correct location on the steering linkage inner tie rod. 4. Install the NEW outer boot clamp (2). 5. Install the steering linkage inner tie rod nut (1) approximately 174 mm (6.85 in) (a) from the outer boot clamp. 6. Install the steering linkage outer tie rod. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). 7. Measure and adjust the front toe. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (See: Alignment/Service and Repair/Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment). 8. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot Replacement > Page 5754 Steering Gear: Service and Repair Steering Gear Replacement Steering Gear Replacement Special Tools EN-45059 - Angle Meter For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Disconnect the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 2. Turn the front wheels to the straight forward position and secure the steering wheel from moving. 3. Disconnect the intermediate steering shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement (See: Steering Column/Service and Repair/Intermediate Steering Shaft Replacement). 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 5. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 6. Remove the front compartment insulator, if equipped. Refer to Front Compartment Insulator Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Insulator Replacement). 7. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 8. Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement (See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair). 9. Disconnect the steering linkage outer tie rod from the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot Replacement > Page 5755 10. Use an allen wrench in order to hold the stabilizer shaft link ball stud. Remove the lower stabilizer link shaft nut (2) on both sides. DISCARD the nuts. 11. Disconnect the stabilizer shaft link (1) from the stabilizer shaft. 12. Remove the 4 fasteners (1) from the engine side cover on both sides. 13. Remove the 4 fasteners (1) from the front engine compartment cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot Replacement > Page 5756 14. Remove the front transmission mount bracket bolt (1). 15. Remove the rear transmission mount bracket bolt (2). 16. Remove the 2 rear suspension frame bolts (2). DISCARD the bolts. 17. Remove the rear frame reinforcements (1). 18. Lower the drivetrain and front suspension frame 55 mm (2 in) in order to access the steering gear. Refer to Drivetrain and Front Suspension Frame Replacement (See: Suspension/Subframe/Front Subframe/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot Replacement > Page 5757 Note: Connector latches are difficult to access 19. Disconnect the electrical connector (3). 1. Use a flat blade tool in order to release the lock (2) in the direction of the arrow. 2. Use a flat blade tool in order to push down the latch (1) and pull off the electrical connector. 20. Disconnect electrical connector (2). 1. Use an angled flat blade tool in order to gently lift the latch (3). 2. Pull off the electrical connector (2). 21. Disconnect electrical connector (1). 1. Use an angled flat blade tool in order to gently lift the latch (4). 2. Pull off the electrical connector (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot Replacement > Page 5758 22. Use a suitable tool in order to carefully disconnect the 2 wiring harness plugs (3) from the steering gear. 23. Remove the 2 wiring harness bracket bolts (4). 24. Remove the bracket (2). 25. Disconnect the wiring harness retainer (1) from the steering gear. 26. Remove the 2 right stabilizer shaft insulator clamp bolts (2). DISCARD the bolts. 27. Use mechanics wire in order to hold the stabilizer shaft (1) to the body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot Replacement > Page 5759 28. Remove the 2 steering gear bolts (4) and the nuts (1, 3) from front suspension frame. DISCARD the nuts and the bolts. 29. Carefully remove the steering gear (2) through the right front wheel house. 30. If necessary, refer to the following procedures: * Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement) * Steering Linkage Inner Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Inner Tie Rod Replacement) * Steering Gear Boot Replacement (See: Steering Gear Boot Replacement) Installation Procedure Caution: Ensure that the steering column dash seal is installed properly onto steering gear rack pinion housing. The sealing lip MUST rest on lower steering column cover surface evenly. To ease installation of the seal, apply liquid soap to the sealing lip. After installation, verify that the seal lip does not protrude into the vehicle's interior. Improper installation could result in poor sealing performance and water intrusion into the vehicle. Note: Check correct wiring routing in order to assure correct installation. 1. Carefully install the steering gear (2) through the right front wheel house and position the steering gear on the frame. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot Replacement > Page 5760 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the NEW steering gear bolts (4) and the NEW nuts (1, 3) and tighten to 110 Nm (81 lb ft). 3. Use the EN-45059 - sensor in order to tighten the steering gear bolts and nuts an additional 150 degrees to 160 degrees. 4. Install the wiring harness bracket (2). 5. Install the 2 wiring harness bracket bolts (4) and tighten to 9 Nm (80 lb in). 6. Connect the wiring harness retainer (1) to steering gear. 7. Connect the 2 wiring harness plugs (3) to the steering gear. Note: Connector latches are difficult to access 8. Connect the electrical connector (1). Push on the connector body until you hear a click. 9. Connect the electrical connector (2). Push on the connector body until you hear a click. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot Replacement > Page 5761 10. Connect electrical connector (3). Push on the connector body until you hear a click. 11. Push the lock (2) in the opposite direction of the arrow until you hear a click. 12. Remove the mechanics wire from the stabilizer shaft (1). 13. Position the stabilizer shaft and the bracket onto the suspension frame. 14. Install the NEW right stabilizer shaft insulator clamp bolts (2) and tighten to 22 Nm (16 lb ft). 15. Use the EN-45059 - sensor in order to tighten the NEW right stabilizer shaft insulator clamp bolts an additional 30 degrees. 16. Install the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement (See: Suspension/Subframe/Front Subframe/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot Replacement > Page 5762 17. Install the frame reinforcements (1). 18. Install the NEW frame rear bolts (2) and tighten to 160 Nm (118 lb ft). 19. Install the front transmission mount bolt (1) and tighten to 58 Nm (43 lb ft). 20. Install the rear transmission mount bracket bolt (2) and tighten to 100 Nm (74 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot Replacement > Page 5763 21. Install the 4 fasteners (1) to the engine side cover on both sides. 22. Install the 4 fasteners (1) to the front engine compartment cover. 23. Install the front compartment insulator, if equipped. Refer to Front Compartment Insulator Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Insulator Replacement). 24. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 25. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement (See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair). 26. Connect the steering linkage outer tie rod to the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Boot Replacement > Page 5764 27. Connect the stabilizer shaft link (1) to the stabilizer shaft on both sides. 28. Install the NEW lower stabilizer link shaft nut (2) on both sides. Use an allen wrench in order to hold the stabilizer shaft link ball stud. Tighten the lower stabilizer link shaft nut to 35 Nm (26 lb ft). 29. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 30. Lower the vehicle. 31. Connect the intermediate steering shaft to the steering gear. Refer to Intermediate Steering Shaft Replacement (See: Steering Column/Service and Repair/Intermediate Steering Shaft Replacement). 32. Connect the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 33. Measure and adjust the wheel alignment. Refer to Wheel Alignment Measurement (See: Alignment/Service and Repair/Wheel Alignment Measurement). 34. Center the steering angle sensor and learn the software end stops. Refer to Power Steering Control Module Calibration (See: Power Steering/Steering Control Module/Service and Repair). 35. Program the power steering control module. Refer to Power Steering Control Module Programming and Setup (See: Testing and Inspection/Programming and Relearning/Power Steering Control Module Programming and Setup). 36. Program the Volatile Memory. Refer to Volatile Memory Programming (See: Testing and Inspection/Programming and Relearning/Volatile Memory Programming). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Locations Steering Mounted Controls Transmitter: Locations Instrument Panel/Center Console Component Views Top of the Steering Column Components 1 - S70R Steering Wheel Controls Switch - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Locations > Page 5768 Steering Mounted Controls Transmitter: Diagrams Component Connector End Views S70R Steering Wheel Controls Switch - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair Steering Shaft: Service and Repair Intermediate Steering Shaft Replacement Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. Disable the supplemental inflatable restraint system. Refer to SIR Disabling and Enabling (See: Steering Column/Air Bag(s) Arming and Disarming/Service and Repair). 2. Turn the steering wheel to the straight forward position and support it from movement. 3. Remove the 2 intermediate steering shaft bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Page 5772 4. Remove the intermediate steering shaft (1). Installation Procedure 1. Install the intermediate steering shaft (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Page 5773 2. Push upper universal joint onto steering column carefully as described in the above note. 3. Push down lower universal joint onto steering gear pinion. Insert lower bolt (2) with thread lock compound. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Steering Column/Specifications/Fluid Type Specifications). Note: The recess (2) of the fine toothing in the universal joint have to align precisely with the recess (1) of the fine toothing on the steering pinion. The bore in the universal joint has to align with the groove on the steering pinion (3). 4. Push universal joint onto steering pinion carefully as described in the above note. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Page 5774 5. Apply thread lock adhesive to upper shaft bolt. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Steering Column/Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the 2 intermediate steering shaft bolts (1). Tighten the intermediate steering shaft bolts 34 Nm (25 lb ft). 7. Center the steering angle sensor. Refer to Steering Angle Sensor Centering (See: Sensors and Switches - Steering/Steering Angle Sensor/Service and Repair/Procedures). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Recalls for Steering Wheel: > NHTSA11V221000 > Apr > 11 > Recall 11V221000: Potential Steering Wheel Detachment Steering Wheel: Recalls Recall 11V221000: Potential Steering Wheel Detachment VEHICLE MAKE/MODEL: MODEL YEAR(S): Chevrolet/Cruze 2011 MANUFACTURER: General Motors Corp. MFR'S REPORT DATE: April 06, 2011 NHTSA CAMPAIGN ID NUMBER: 11V221000 NHTSA ACTION NUMBER: N/A COMPONENT: Steering POTENTIAL NUMBER OF UNITS AFFECTED: 2,100 SUMMARY: General Motors is recalling certain model year 2011 Chevrolet Cruze vehicles. During manufacturing the steering wheel could have been improperly fastened and may detach from the steering column. CONSEQUENCE: Should the steering wheel detach from the steering column while driving, the driver could lose the ability to steer the vehicle, increasing the risk of a crash. REMEDY: Dealers will inspect to ensure that the steering wheel is assembled properly. This service will be performed for you free of charge. The safety recall began on April 7, 2011. Owners may contact Chevrolet at 1-800-630-2438, or at The Owner Center at www.gmownercenter.com. NOTES: GM'S safety recall No. 11094. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Recalls for Steering Wheel: > 11094 > Apr > 11 > Recall - Steering Wheel Fastener Inspection Technical Service Bulletin # 11094 Date: 110405 Recall - Steering Wheel Fastener Inspection SAFETY Bulletin No.: 11094 Date: April 05, 2011 Subject: 11094 - Steering Wheel Fastener Inspection Models: 2011 Chevrolet Cruze The vehicles involved in this safety recall were previously included in PIE0158. PIE0158 will be closed and all vehicles that did not have the inspection performed will be transferred to this safety recall. Condition General Motors has decided that a defect, which relates to motor vehicle safety, may exist in certain 2011 model year Chevrolet Cruze vehicles. In the unlikely event that an assembly plant repair procedure results in an improperly fastened steering wheel, the steering wheel may come loose from the steering column. If this were to happen while the vehicle was moving, the driver could lose the ability to steer the vehicle, potentially leading to a crash. Correction Dealers are to inspect and ensure that the steering wheel is assembled properly. Vehicles Involved Involved are certain 2011 model year Chevrolet Cruze vehicles. Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. * NO vehicles are expected to require a steering wheel bolt. Service Procedure 1. Start the vehicle and rotate steering wheel to position the access holes above the steering column. Place the ignition in the OFF position. 2. Disconnect the negative battery cable to disable the supplemental inflatable restraint (SIR) system. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Remove the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Recalls for Steering Wheel: > 11094 > Apr > 11 > Recall - Steering Wheel Fastener Inspection > Page 5787 4. Insert suitable tools to the openings (2) on both sides of the steering wheel (1). 5. Release the springs in direction of the arrows. 6. Remove Driver Airbag Module (DAB). DO NOT disconnect the two yellow electrical connectors. 7. Inspect the hub area of the steering wheel for the attachment bolt (1). - If the attachment bolt (1) is NOT present, install a new attachment bolt, P/N 11610164. Apply Medium Strength Threadlocker - Blue Loctite(R) 242 (or equivalent) to the attachment bolt threads and tighten the bolt to 30 Nm (23 lb ft). Proceed to Step 8 after installing the new attachment bolt. - If the attachment bolt is present, proceed to Step 8. 8. Reinstall DAB by aligning the two attachment pins to the steering wheel square holes. 9. Push the DAB (1) firmly into the steering column in order the engage the fasteners. Ensure yellow connector wires are routed properly and are not pinched. 10. Install the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement in SI. 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Courtesy Transportation Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Recalls for Steering Wheel: > 11094 > Apr > 11 > Recall - Steering Wheel Fastener Inspection > Page 5788 The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). Dealer Recall Responsibility - For US (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter April 2011 Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Recalls for Steering Wheel: > 11094 > Apr > 11 > Recall - Steering Wheel Fastener Inspection > Page 5789 General Motors has decided that a defect, which relates to motor vehicle safety, may exist in certain 2011 Chevrolet Cruze vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in safety recall 11094. - Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? In the unlikely event that an assembly plant repair procedure was performed on your vehicle, and it resulted in an improperly fastened steering wheel, the steering wheel may come loose from the steering column. If this were to happen while the vehicle was moving, you could lose the ability to steer the vehicle, potentially leading to a crash. What will we do? Your GM dealer will inspect to ensure that the steering wheel is assembled properly. This service will be performed for you at no charge. Because of service scheduling requirements, it is likely that your dealer will need your vehicle longer than the actual inspection time of approximately 20 minutes. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment as soon as possible. If you are concerned about driving your vehicle to your dealer for inspection, you can contact the dealership and they will assist you in getting the vehicle to the dealership. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Jim Moloney General Director, Customer and Relationship Services 11094 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > NHTSA11V221000 > Apr > 11 > Recall 11V221000: Potential Steering Wheel Detachment Steering Wheel: All Technical Service Bulletins Recall 11V221000: Potential Steering Wheel Detachment VEHICLE MAKE/MODEL: MODEL YEAR(S): Chevrolet/Cruze 2011 MANUFACTURER: General Motors Corp. MFR'S REPORT DATE: April 06, 2011 NHTSA CAMPAIGN ID NUMBER: 11V221000 NHTSA ACTION NUMBER: N/A COMPONENT: Steering POTENTIAL NUMBER OF UNITS AFFECTED: 2,100 SUMMARY: General Motors is recalling certain model year 2011 Chevrolet Cruze vehicles. During manufacturing the steering wheel could have been improperly fastened and may detach from the steering column. CONSEQUENCE: Should the steering wheel detach from the steering column while driving, the driver could lose the ability to steer the vehicle, increasing the risk of a crash. REMEDY: Dealers will inspect to ensure that the steering wheel is assembled properly. This service will be performed for you free of charge. The safety recall began on April 7, 2011. Owners may contact Chevrolet at 1-800-630-2438, or at The Owner Center at www.gmownercenter.com. NOTES: GM'S safety recall No. 11094. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 11094 > Apr > 11 > Recall - Steering Wheel Fastener Inspection Technical Service Bulletin # 11094 Date: 110405 Recall - Steering Wheel Fastener Inspection SAFETY Bulletin No.: 11094 Date: April 05, 2011 Subject: 11094 - Steering Wheel Fastener Inspection Models: 2011 Chevrolet Cruze The vehicles involved in this safety recall were previously included in PIE0158. PIE0158 will be closed and all vehicles that did not have the inspection performed will be transferred to this safety recall. Condition General Motors has decided that a defect, which relates to motor vehicle safety, may exist in certain 2011 model year Chevrolet Cruze vehicles. In the unlikely event that an assembly plant repair procedure results in an improperly fastened steering wheel, the steering wheel may come loose from the steering column. If this were to happen while the vehicle was moving, the driver could lose the ability to steer the vehicle, potentially leading to a crash. Correction Dealers are to inspect and ensure that the steering wheel is assembled properly. Vehicles Involved Involved are certain 2011 model year Chevrolet Cruze vehicles. Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. * NO vehicles are expected to require a steering wheel bolt. Service Procedure 1. Start the vehicle and rotate steering wheel to position the access holes above the steering column. Place the ignition in the OFF position. 2. Disconnect the negative battery cable to disable the supplemental inflatable restraint (SIR) system. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Remove the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 11094 > Apr > 11 > Recall - Steering Wheel Fastener Inspection > Page 5799 4. Insert suitable tools to the openings (2) on both sides of the steering wheel (1). 5. Release the springs in direction of the arrows. 6. Remove Driver Airbag Module (DAB). DO NOT disconnect the two yellow electrical connectors. 7. Inspect the hub area of the steering wheel for the attachment bolt (1). - If the attachment bolt (1) is NOT present, install a new attachment bolt, P/N 11610164. Apply Medium Strength Threadlocker - Blue Loctite(R) 242 (or equivalent) to the attachment bolt threads and tighten the bolt to 30 Nm (23 lb ft). Proceed to Step 8 after installing the new attachment bolt. - If the attachment bolt is present, proceed to Step 8. 8. Reinstall DAB by aligning the two attachment pins to the steering wheel square holes. 9. Push the DAB (1) firmly into the steering column in order the engage the fasteners. Ensure yellow connector wires are routed properly and are not pinched. 10. Install the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement in SI. 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Courtesy Transportation Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 11094 > Apr > 11 > Recall - Steering Wheel Fastener Inspection > Page 5800 The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). Dealer Recall Responsibility - For US (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter April 2011 Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 11094 > Apr > 11 > Recall - Steering Wheel Fastener Inspection > Page 5801 General Motors has decided that a defect, which relates to motor vehicle safety, may exist in certain 2011 Chevrolet Cruze vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in safety recall 11094. - Schedule an appointment with your GM dealer. - This service will be performed for you at no charge. Why is your vehicle being recalled? In the unlikely event that an assembly plant repair procedure was performed on your vehicle, and it resulted in an improperly fastened steering wheel, the steering wheel may come loose from the steering column. If this were to happen while the vehicle was moving, you could lose the ability to steer the vehicle, potentially leading to a crash. What will we do? Your GM dealer will inspect to ensure that the steering wheel is assembled properly. This service will be performed for you at no charge. Because of service scheduling requirements, it is likely that your dealer will need your vehicle longer than the actual inspection time of approximately 20 minutes. If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on courtesy transportation. What should you do? You should contact your GM dealer to arrange a service appointment as soon as possible. If you are concerned about driving your vehicle to your dealer for inspection, you can contact the dealership and they will assist you in getting the vehicle to the dealership. Do you have questions? If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Jim Moloney General Director, Customer and Relationship Services 11094 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 5802 Steering Wheel: Description and Operation Steering Wheel and Column Description and Operation The steering wheel and column has 4 primary functions: * Vehicle steering * Vehicle security * Driver convenience * Driver safety Vehicle Steering The steering wheel is the first link between the driver and the vehicle. The steering wheel is fastened to a steering shaft within the column. At the lower end of the column, the intermediate shaft connects the column to the steering gear. Vehicle Security, Found on Some Vehicle Models Theft deterrent components are mounted and designed into the steering column. The following components allow the column to be locked in order to minimize theft: * The ignition switch-location varies * The steering column lock-content varies * The ignition cylinder-location varies * The theft deterrent module-location varies Driver Convenience The steering wheel and column may also have driver controls attached for convenience and comfort. The following controls may be mounted on or near the steering wheel or column. * The turn signal switch * The hazard switch * The headlamp dimmer switch * The wiper/washer switch * The horn pad/cruise control switch * The redundant radio/entertainment system controls * The manual/power tilt or tilt/telescoping functions * The power pedal adjustment control switch * The navigation * The HVAC controls Driver Safety The steering wheel and column has safety features to protect the driver. The following components may be mounted on or near the steering column: Energy-Absorbing Steering Column - The energy-absorbing steering column compresses in the event of a front-end collision, which reduces the chance of injury to the driver. The energy-absorbing feature, collapsible steering shaft, and break away mounting features help reduce the injury in the event of an accident. In addition to these features, the following driver safety features may be on the steering column: SIR Coil and Module - For additional information on the operation of the SIR coil and module, refer to SIR System Description and Operation (See: Restraint Systems/Air Bag Systems/Description and Operation). Steering Wheel Angle Sensor or Steering Wheel Position Sensor - The steering wheel position sensor is located somewhere along the steering shaft assembly. The sensor measures the position of the steering wheel and the speed at which it is rotated. A signal representing this measurement is provided to the vehicle stability enhancement system (VSES) module. The VSES module uses this signal, along with several others representing different vehicle conditions, to monitor the driving behavior of the vehicle and ensure that it stays in control. If the VSES module determines that the vehicle is out of control it provides signals to the powertrain control module (PCM) and the ABS module. These output signals are used to modulate the transmission torque and brake pressure of each of the vehicles wheels in order to regain control of the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 5803 Steering Wheel: Service and Repair Steering Wheel Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Testing and Inspection > Steering Linkage Inner Tie Rod Inspection Tie Rod: Testing and Inspection Steering Linkage Inner Tie Rod Inspection Steering Linkage Inner Tie Rod Inspection Special Tools GE-8001 - Dial Indicator Set For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: This inspection procedure does not supersede local government required inspections that have more stringent requirements. 1. Turn the ignition key to the ON position with the engine OFF. 2. With the aid of an assistant, turn the steering wheel to the full stop position and hold the steering wheel in that position until the test is complete. The tie rod being tested should be inside the steering gear housing seated against the steering stop. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 4. If there is not a good location for the GE-8001 - dial indicator pointer at the steering gear housing, install a large worm gear hose clamp to the steering gear housing over the larger steering gear boot clamp and align the clamp so that the screw can be a location for the GE-8001 - dial indicator pointer. 5. Install the GE-8001 - dial indicator between the inner tie rod (2) and the steering gear housing or the worm gear clamp in such a way as to measure the lash between the inner tie rod and the steering gear housing. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Testing and Inspection > Steering Linkage Inner Tie Rod Inspection > Page 5808 Note: Only move the tire enough to feel any lash between the inner tie rod and the inner tie rod housing without moving the steering gear rack. 6. Grasping the tire at the 3 o'clock (2) and 9 o'clock (1) positions, gently push in on one side of the tire in order to remove any lash. 7. Zero the GE-8001 - dial indicator. 8. On the same side of the tire previously pushed in, gently pull out and measure the lash. 9. Record the measurement shown on the GE-8001 - dial indicator. 10. If the measured value exceeds 0.5 mm (0.02 in), replace the inner tie rod. Refer to Steering Linkage Inner Tie Rod Replacement (See: Service and Repair/Steering Linkage Inner Tie Rod Replacement). 11. Repeat the procedure for the other side. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Testing and Inspection > Steering Linkage Inner Tie Rod Inspection > Page 5809 Tie Rod: Testing and Inspection Steering Linkage Outer Tie Rod Inspection Steering Linkage Outer Tie Rod Inspection Special Tools GE-8001 - Dial Indicator Set For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: This inspection procedure does not supersede local government required inspections that have more stringent requirements. 1. Inspect the outer tie rod seal. If the outer tie rod seal is torn, replace the outer tie rod. Refer to Steering Linkage Outer Tie Rod Replacement ( See: Service and Repair/Steering Linkage Outer Tie Rod Replacement). 2. Raise the side of the vehicle being inspected with a floor jack while maintaining contact between the opposite wheel and the shop floor. Support the lower control arm with a floor jack stand as far outboard as possible and remove the floor jack. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 3. Install the GE-8001 - dial indicator between the outer tie rod and the steering knuckle as shown in the graphic. Note that the tire and wheel assembly is shown removed only for clarification of the GE-8001 - dial indicator position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Testing and Inspection > Steering Linkage Inner Tie Rod Inspection > Page 5810 4. Grasping the tire at the 3 o'clock (2) and 9 o'clock (1) positions, gently push in on one side of the tire to remove any lash. 5. Zero the GE-8001 - dial indicator. 6. On the same side of the tire previously pushed inwards, gently pull outwards and measure the lash. 7. Record the measurement shown on the GE-8001 - dial indicator. 8. If the measured value exceeds 0.5 mm (0.02 in), replace the outer tie rod. Refer to Steering Linkage Outer Tie Rod Replacement (See: Service and Repair/Steering Linkage Outer Tie Rod Replacement). 9. Repeat the procedure for the other side. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Inner Tie Rod Replacement Tie Rod: Service and Repair Steering Linkage Inner Tie Rod Replacement Steering Linkage Inner Tie Rod Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the steering gear boot. Refer to Steering Gear Boot Replacement (See: Steering Gear/Service and Repair/Steering Gear Boot Replacement). 3. Turn the steering wheel in order to position the steering gear rack so that only 2 rack teeth and the flat surface of the rack are visible outside the steering gear housing. 4. Place a soft jaw pipe wrench or soft jaw pliers on the flat surface of the steering gear rack (3) between the steering gear housing (4) and the inner tie rod housing (2). 5. Place a crows foot wrench on the flats of the inner tie rod housing. Caution: Do not change the steering gear preload adjustment before moving the inner tie rod from the steering gear. Changing the steering gear preload adjustment before moving the inner tie rod could result in damage to the pinion and the steering gear. 6. Rotate the steering linkage inner tie rod housing counterclockwise while holding the steering gear rack stationary until the steering linkage inner tie rod separates from the steering gear rack. Installation Procedure 1. Install the steering linkage inner tie rod to the steering gear rack. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Inner Tie Rod Replacement > Page 5813 2. Place a soft jaw pipe wrench or soft jaw pliers on the flat surface of the steering gear rack (3) between the steering gear housing (4) and the inner tie rod housing (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Place a torque wrench with a crows foot wrench attachment on the flats of the inner tie rod housing and tighten to 105 Nm (77 lb ft). 4. Install the steering gear boot. Refer to Steering Gear Boot Replacement (See: Steering Gear/Service and Repair/Steering Gear Boot Replacement ). 5. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Inner Tie Rod Replacement > Page 5814 Tie Rod: Service and Repair Steering Linkage Outer Tie Rod Replacement Steering Linkage Outer Tie Rod Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Inner Tie Rod Replacement > Page 5815 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Rear Axle Bracket Replacement Axle Beam: Service and Repair Rear Axle Bracket Replacement Rear Axle Bracket Replacement Special Tools EN-45059 - Torque Angle Sensor Kit For equivalent regional tools. Refer to Special Tools (See: Tools and Equipment/Rear Suspension) Removal Procedure Warning Use of eye goggles is necessary to prevent personal injury. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Using a drill 6 mm (0.2 in) drill bit, drill 2 holes (1) through the rear axle bracket and into the underbody (2). These holes (1) will be used by guide pins to properly align the rear axle bracket to the underbody (2). 3. Support the rear axle with a hydraulic lift table. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Rear Axle Bracket Replacement > Page 5821 Note: Service one side at a time, the other side must be installed 4. Remove and DISCARD 4 rear axle bracket bolts (1). 5. Remove and DISCARD the rear axle bushing bolts and nuts (1) from the rear axle (2). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Rear Axle Bracket Replacement > Page 5822 Note: The axle bushing bolts (1) and nuts must be tightened with the axle at the correct trim height. 1. Loosely install the NEW rear axle bushing bolts and nuts (1) to the rear axle (2). 2. Loosely install the 4 NEW axle bracket bolts (1). 3. Apply anti-corrosion treatment to the guide pin holes in the underbody and rear axle bracket. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Rear Axle Bracket Replacement > Page 5823 4. Using 6 mm (0.2 in) drill bits (2) as guide pins, align the rear axle bracket (1) to the underbody. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the axle bracket bolts (1) to 90 Nm (66 lb ft) + 45° , using EN-45059 - angle meter. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Rear Axle Bracket Replacement > Page 5824 6. Using the lift table, raise the axle to the proper trim height specification by measuring the vertical distance between the bottom edge of the upper spring seat and the bottom of the notch in the lower spring seat. Dimension (a): 217 mm (8.54 in) 7. Tighten the axle bushing through bolts (1) and nuts and tighten to 70 Nm (52 lb ft) + 120° , using EN-45059 - angle meter. 8. Remove the hydraulic lift table from the rear axle. 9. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Rear Axle Bracket Replacement > Page 5825 Axle Beam: Service and Repair Rear Axle Bushing Replacement (Watt Linkage) Rear Axle Bushing Replacement (Watt Linkage) Special Tools * CH-906-42 - Adapter * CH-6615-10 - Hydraulic Cylinder * CH-6616 - Hydraulic Hand Pump * CH-49459 - Adapter For equivalent regional tools. Refer to Special Tools (See: Tools and Equipment/Rear Suspension). Removal Procedure Warning Use of eye goggles is necessary to prevent personal injury. 1. Remove the rear axle. Refer to Rear Axle Replacement (Watt Linkage) (See: Rear Axle Replacement (Watt Linkage)). 2. With the aid of second mechanic, place rear axle onto work bench. 3. Mark installation position (1) for rear axle bushing (12) on rear axle using a permanent marker. Use upper gap of bushing for alignment. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Rear Axle Bracket Replacement > Page 5826 4. Drill 8 holes through the rubber bushing (1) with a 10 mm (0.4 in) drill bit. 5. Carefully cut around the bushing core (1) using a jigsaw or similar tool. Use the lowest hole (2) to insert saw. 6. Remove the bushing core from the bushing. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Rear Axle Bracket Replacement > Page 5827 7. Remove bushing (1), using a suitable tool (2) and a hammer. 8. Mark installation position (2) of NEW rear axle bushing (1) as shown in graphic above. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Rear Axle Bracket Replacement > Page 5828 9. Align bushing marking (1) to rear axle marking (2). 10. Install the following components to rear axle bushing and rear axle: * CH-6615-10 - cylinder (1). * CH-49459 - adapter (2). * NEW rear axle bushing (3). * CH-906-42 - adapter (4) * Install and tighten counter nut (5) onto spindle of CH-6615-10 - cylinder (1) 11. Connect pressure hose (6) of CH-6616 - pump to CH-6615-10 - cylinder. 12. Carefully press the rear axle bushing (3) into the rear axle, using CH-6616 - pump. 13. When the CH-6615-10 cylinder reaches the operating limit, release the pressure on CH-6616 - pump , retighten the nut (5) and continue to press the rear axle bushing into rear axle to the final installed position. 14. Remove ALL special tools. 15. Install rear axle. Refer to Rear Axle Replacement (Watt Linkage) (See: Rear Axle Replacement (Watt Linkage)). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Rear Axle Bracket Replacement > Page 5829 Axle Beam: Service and Repair Rear Axle Replacement (Watt Linkage) Rear Axle Replacement (Watt Linkage) Special Tools EN-45059 - Angle Meter For equivalent regional tools. Refer to Special Tools (See: Tools and Equipment/Rear Suspension). Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Remove both brake hose bolts (1) attaching the hose to the rear brake caliper bracket. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Rear Axle Bracket Replacement > Page 5830 4. Remove rear parking brake cable bracket bolts (1) from the rear axle. 5. Remove and DISCARD the wheel bearing/hub mounting bolts (1). Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 6. Without disconnecting the hydraulic brake flexible hose, remove wheel bearing/hub and brake assembly (2) upward and secure the wheel bearing/hub and brake assembly with heavy mechanics wire (1), or equivalent. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Rear Axle Bracket Replacement > Page 5831 7. Using a 6 mm (0.2 in) drill bit, drill 2 holes (1) through the right rear axle bracket and into the underbody. Repeat this step for the left rear axle bracket. These holes (1) will be used by guide pins to properly align the rear axle brackets to the underbody (2). 8. Support the rear axle with a hydraulic lift table. 9. Remove the lower shock absorber bolts. Refer to Shock Absorber Replacement (See: Suspension Strut / Shock Absorber/Service and Repair/Rear Suspension/Shock Absorber Replacement). 10. Remove and DISCARD the equalizer beam link bolts (1), if equipped. 11. Lower the hydraulic lift table and remove the rear coil springs. Refer to Rear Spring Replacement (See: Suspension Spring ( Coil / Leaf )/Service and Repair/Rear Suspension/Rear Spring Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Rear Axle Bracket Replacement > Page 5832 12. Remove and DISCARD the 8 rear axle bracket bolts (1) from the right and left rear axle brackets. 13. Use the hydraulic lift table to lower the rear axle (1) from the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Rear Axle Bracket Replacement > Page 5833 14. Remove the rear coil spring lower seat insulators (1) from the axle. 15. Remove and DISCARD the rear axle bushing bolts and nuts (1) from the rear axle (2). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Rear Axle Bracket Replacement > Page 5834 Note: The axle bushing bolts (1) and nut connection must be tightened with the axle at the correct trim height. 1. Loosely install the NEW rear axle bushing bolts and nuts (1) to the rear axle (2). 2. Install the rear coil spring lower seat insulators (1) to the axle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Rear Axle Bracket Replacement > Page 5835 3. Raise the axle (1) into position. 4. Loosely install the NEW axle bracket bolts (1) to the right and left rear axle brackets. 5. Apply anti-corrosion treatment to the guide pin holes in the underbody and rear axle brackets. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Rear Axle Bracket Replacement > Page 5836 6. Using 6 mm (0.2 in) drill bits (2) as guide pins, align the right and left rear axle brackets to the underbody (1). Warning: Refer to Torque-to-Yield Fastener Warning (See: Engine, Cooling and Exhaust/Engine/Timing Components/Service Precautions/Torque-to-Yield Fastener Warning). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Tighten the NEW axle bracket bolts (1) and tighten to 90 Nm (66 lb ft) + 45° , using the EN-45059 - angle meter. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Rear Axle Bracket Replacement > Page 5837 8. Using the lift table, raise the axle to the proper trim height specification by measuring the vertical distance (a) between the center of the wheel hub (2) and top of the wheel opening (1). Dimension (a): 385 mm (15.16 in) Warning: Refer to Torque-to-Yield Fastener Warning (See: Engine, Cooling and Exhaust/Engine/Timing Components/Service Precautions/Torque-to-Yield Fastener Warning). 9. Tighten the NEW axle bushing through bolts (1) and nuts and tighten to 70 Nm (52 lb ft) + 120° , using the EN-45059 - angle meter. 10. Install the rear coil springs. Refer to Rear Spring Replacement (See: Suspension Spring ( Coil / Leaf )/Service and Repair/Rear Suspension/Rear Spring Replacement). 11. Install the lower shock absorber bolts. Refer to Shock Absorber Replacement (See: Suspension Strut / Shock Absorber/Service and Repair/Rear Suspension/Shock Absorber Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Rear Axle Bracket Replacement > Page 5838 12. Install the equalizer beam link bolts (1) and tighten to 160 Nm (118 lb ft) , if equipped. 13. Remove the hydraulic lift table from the rear axle. 14. Install the wheel bearing/hub and brake assembly. 15. Install the NEW wheel bearing/hub mounting bolts (1) and tighten to 50 Nm (37 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Rear Axle Bracket Replacement > Page 5839 16. Install rear parking brake cable bracket bolts (1) at the rear axle and tighten to 10 Nm (89 lb in). 17. Install both brake hose bolts (1) attaching the hose to the rear brake caliper bracket and tighten. 18. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 19. Remove the support and lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection Ball Joint: Testing and Inspection Ball Joint Inspection 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Clean and inspect the ball joint seal for cuts or tears. If the ball joint seal is damaged, replace the lower control arm. Refer to Lower Control Arm Replacement (See: Control Arm/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair Control Arm Bushing: Service and Repair Front Lower Control Arm Bushing Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Steering Knuckle Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Procedures Steering Angle Sensor: Procedures Steering Angle Sensor Centering The external column mounted steering angle sensor does not require a centering often. Centering of the steering angle sensor might be required after certain service procedures are performed. Some of these procedures are as follows: * Electronic brake control module (EBCM) replacement * Steering angle sensor replacement * Steering gear replacement * Steering column replacement * Collision or other physical damage The external column mounted steering angle sensor centering procedure can be completed with a scan tool using the following steps: 1. Using the steering wheel, align the front wheels forward. 2. Apply the parking brake, or set the transmission in the P position. 3. Install the scan tool to the data link connector. 4. Ignition ON, engine OFF 5. Select Steering Wheel Angle Sensor Reset in the Steering Wheel Angle Sensor Module Configuration/Reset Functions list. 6. Follow the scan tool directions to complete the learn procedure. 7. Select Steering Wheel Angle Sensor Learn in the Steering Wheel Angle Sensor Module Configuration/Reset Functions list. 8. Follow the scan tool directions to complete the learn procedure. 9. Select Steering Wheel Angle Sensor Learn in the EBCM Configuration/Reset Functions list. 10. Follow the scan tool directions to complete the learn procedure. 11. Clear any DTCs that may be set. 12. If equipped with electric power steering (EPS), perform the Software Endstop Learning. Refer to Power Steering Control Module Calibration ( See: Relays and Modules - Steering and Suspension/Relays and Modules - Steering/Steering Control Module/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Procedures > Page 5856 Steering Angle Sensor: Removal and Replacement Steering Angle Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension Stabilizer Link: Service and Repair Front Suspension Stabilizer Shaft Link Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 5862 Stabilizer Link: Service and Repair Rear Suspension Equalizer Beam Center Link Heat Shield Replacement Equalizer Beam Center Link Heat Shield Replacement Equalizer Beam Center Link Replacement Equalizer Beam Center Link Replacement Special Tools EN-45059 - Torque Angle Sensor Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment/Rear Suspension). Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 5863 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Remove and DISCARD exhaust front pipe to exhaust rear muffler nuts (2, 3). 4. Remove rear exhaust pipe (1) from flange. 5. DISCARD flange gasket. Note: There may be additional attachment points, depending on the powertrain in the vehicle. 6. Loosen rear exhaust muffler from suspension points (1, 2, 3). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 5864 7. Remove 3 rivets (1) from equalizer beam center link heat shield (2). 8. Remove the equalizer beam link bolt (1) from the rear axle (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 5865 9. Remove and DISCARD the equalizer beam link bolt and nut (1) from equalizer beam link (2). 10. Remove the right equalizer beam link bolt (2) from the rear axle (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 5866 11. Remove the left equalizer beam link bolt (1) from the rear axle (2). Note: Remember the correct installation position. 12. Push down rear muffler and remove and discard the equalizer beam center link bolt and nut (1) from equalizer beam center link (2). 13. Remove the equalizer beam center link (2) from the vehicle. Installation Procedure 1. Install the equalizer beam center link (2) to the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 5867 2. Using the lift table, raise the axle to the proper trim height specification by measuring the vertical distance (a) between the center of the wheel hub (2) and top of the wheel opening (1). Dimension (a): 385 mm (15.16 in) Warning: Refer to Torque-to-Yield Fastener Warning (See: Engine, Cooling and Exhaust/Engine/Timing Components/Service Precautions/Torque-to-Yield Fastener Warning). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Remember the correct installation position from the removal. 3. Push down rear muffler and install the equalizer beam center link bolt and nut (1) to equalizer beam center link (2) and tighten to 70 Nm (30 lb ft) +45°- 60°. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 5868 Warning: Refer to Torque-to-Yield Fastener Warning (See: Engine, Cooling and Exhaust/Engine/Timing Components/Service Precautions/Torque-to-Yield Fastener Warning). 4. Install the left NEW equalizer beam link bolt and nut (2) to equalizer beam link (1) and tighten to 40 Nm (30 lb ft) + 60°. Warning: Refer to Torque-to-Yield Fastener Warning (See: Engine, Cooling and Exhaust/Engine/Timing Components/Service Precautions/Torque-to-Yield Fastener Warning). 5. Install the right NEW equalizer beam link bolt and nut (2) to equalizer beam link (1) and tighten to 40 Nm (30 lb ft) + 60°. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 5869 6. Install the left equalizer beam link bolt (1) to the rear axle (2) and tighten to 160 Nm (118 lb ft). 7. Install the right equalizer beam link bolt (1) to the rear axle (2) and tighten to 160 Nm (118 lb ft). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 5870 8. Install 3 rivets (1) to equalizer beam center link heat shield (2). Note: There may be additional attachment points, depending on the powertrain in the vehicle. 9. Install rear exhaust muffler to suspension points (1, 2, 3). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 5871 10. Install NEW flange gasket. 11. Install rear exhaust pipe (1) to flange. Caution: Torque-to-Yield Fastener Caution (See: Engine, Cooling and Exhaust/Engine/Timing Components/Service Precautions/Torque-to-Yield Fastener Caution) 12. Install NEW exhaust front pipe to exhaust rear muffler nuts (2, 3) and tighten to 17 Nm (13 lb ft). 13. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair) 14. Lower the vehicle. Equalizer Beam Link Replacement - Left Side Equalizer Beam Link Replacement - Left Side Special Tools EN-45059 - Angle Sensor Kit For equivalent regional tools. Refer to Special Tools (See: Tools and Equipment/Rear Suspension). Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 5872 3. Remove and DISCARD exhaust front pipe to exhaust rear muffler nuts (2, 3). 4. Remove rear exhaust pipe (1) from flange. 5. DISCARD flange gasket. Note: There may be additional attachment points, depending on the powertrain in the vehicle. 6. Loosen rear exhaust muffler from suspension points (1, 2, 3). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 5873 7. Remove 3 rivets (1) from equalizer beam center link heat shield (2). 8. Remove the equalizer beam link bolt (1) from the rear axle (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 5874 9. Remove and discard the equalizer beam link bolt and nut (1) from equalizer beam center link (2). 10. Remove equalizer beam link from the vehicle. Installation Procedure 1. Insert equalizer beam link to the vehicle. Note: Following step must be proceed in order to achieve correct rear axle joints alignment. 2. Using the lift table, raise the axle to the proper trim height specification by measuring the vertical distance (a) between the center of the wheel hub (2) and top of the wheel opening (1). Dimension (a): 385 mm (15.16 in) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 5875 Warning: Refer to Torque-to-Yield Fastener Warning (See: Engine, Cooling and Exhaust/Engine/Timing Components/Service Precautions/Torque-to-Yield Fastener Warning). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the NEW equalizer beam link bolt and nut (1) to equalizer beam center link (2) and tighten to 40 Nm (30 lb ft) + 60° , using the EN-45059 - angle meter. 4. Instal the equalizer beam link bolt (1) to the rear axle (2) and tighten to 160 Nm (118 lb ft). 5. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 5876 6. Install 3 rivets (1) to equalizer beam center link heat shield (2). Note: There may be additional attachment points, depending on the powertrain in the vehicle. 7. Install rear exhaust muffler to suspension points (1, 2, 3). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 5877 8. Install NEW flange gasket. 9. Install rear exhaust pipe (1) to flange. Caution: Refer to Torque-to-Yield Fastener Caution (See: Engine, Cooling and Exhaust/Engine/Timing Components/Service Precautions/Torque-to-Yield Fastener Caution) 10. Install NEW exhaust front pipe to exhaust rear muffler nuts (2, 3) and tighten to 17 Nm (13 lb ft). 11. Lower the vehicle. Equalizer Beam Link Replacement - Right Side Equalizer Beam Link Replacement - Right Side Special Tools EN-45059 - Angle Sensor Kit For equivalent regional tools. Refer to Special Tools (See: Tools and Equipment/Rear Suspension). Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 5878 3. Remove 3 rivets (1) from equalizer beam center link heat shield (2). 4. Remove the equalizer beam link bolt (1) from the rear axle (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 5879 5. Remove and discard the equalizer beam link bolt and nut (1) from equalizer beam center link (2). 6. Remove the equalizer beam link from the vehicle. Installation Procedure 1. Insert equalizer beam link to the vehicle. Note: Following step must be proceed in order to achieve correct rear axle joints alignment. 2. Using the lift table, raise the axle to the proper trim height specification by measuring the vertical distance (a) between the center of the wheel hub (2) and top of the wheel opening (1). Dimension (a): 385 mm (15.16 in) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 5880 Warning: Refer to Torque-to-Yield Fastener Warning (See: Engine, Cooling and Exhaust/Engine/Timing Components/Service Precautions/Torque-to-Yield Fastener Warning). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the NEW equalizer beam link bolt and nut (1) to equalizer beam center link (2) and tighten to 40 Nm (30 lb ft) + 60° , using the EN-45059 - angle meter. 4. Install and hand tighten the equalizer beam link bolt (1) to the rear axle (2) and tighten to 160 Nm (118 lb ft). 5. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 6. Lower the vehicle to ground. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 5881 7. Install 3 rivets (1) to equalizer beam center link heat shield (2). 8. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair Front Subframe: Service and Repair Drivetrain and Front Suspension Frame Replacement Removal Procedure 1. Support the radiator and condenser from above using the condenser tabs on each side. 2. Remove the lower steering intermediate shaft bolt (1). 3. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle . 4. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation . 5. Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement . 6. Remove the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Splash Shield Replacement). 7. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 8. Remove the front compartment insulator, if equipped. Refer to Front Compartment Insulator Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Insulator Replacement). 9. Remove the wheel speed sensor wiring harness (2) from the frame on both sides. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Page 5886 Remove the wiring harness retainers (3) from the frame and the lower control arm. 10. Remove the radiator wiring harness (1) from the frame. Remove the wiring harness retainers (4) from the frame. 11. Remove the lower ball joints from the steering knuckles. Refer to Lower Control Arm Replacement . 12. Remove the stabilizer link nut (1) from the strut. 13. Remove the outer tie rods and tie rod nuts from the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement . 14. Remove the front (1) and the rear (2) transmission mount bracket bolts. 15. Install the engine support fixture. For the 1.4L engine, refer to Engine Support Fixture . For the 1.8L engine, refer to Engine Support Fixture . 16. Turn the front wheels to the straight forward position and secure the steering wheel from moving. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Page 5887 17. Carefully disconnect 2 wiring harness plugs (3) from the steering gear with a suitable tool. Use the following procedure to disconnect the 2 wiring harness plugs: 1. Insert a small flat bladed tool into the pocket of the connector retention feature. 2. Gently move the retention feature back and pull on the connector to disconnect the connector. 18. Using a suitable engine support table or equivalent, lower the vehicle until the drivetrain and front suspension frame contacts the engine support table. 19. Secure the power steering gear to the vehicle. 20. Remove the frame front bolts (1). 21. Remove the frame rear bolts (2). 22. Remove the frame reinforcements (3). 23. Remove the frame (4) from the vehicle. 24. Remove the following components if replacing the frame: * The lower control arms-Refer to Lower Control Arm Replacement . * The stabilizer shaft-Refer to Stabilizer Shaft Replacement . * The radiator support brackets. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Page 5888 * The steering gear-Refer to Steering Gear Replacement . Installation Procedure 1. Install the following components on the drivetrain and front suspension frame if removed: * The radiator support brackets. * The stabilizer shaft-Refer to Stabilizer Shaft Replacement . * The lower control arms-Refer to Lower Control Arm Replacement . * The steering gear-Refer to Steering Gear Replacement . 2. Install the frame (4) into the vehicle. 3. Install the frame reinforcements (3). Caution: Refer to Fastener Caution . 4. Install the frame rear bolts (2) and tighten to 160 Nm (118 lb ft). 5. Install the frame front bolts (1) and tighten to 160 Nm (118 lb ft). 6. Remove the support for the power steering gear. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Page 5889 7. Install and tighten 2 wiring harness bracket bolts (4) to 9 Nm (80 lb in). 8. Tighten wiring harness retainer (1) to steering gear. 9. Connect 2 wiring harness plugs (3). 10. Install the front bumper energy absorber bracket bolt. 11. Install the front transmission mount bolt (1) and tighten to 100 Nm (74 lb ft). 12. Install the rear transmission mount bracket bolt (2) and tighten to 100 Nm (74 lb ft). 13. Install the outer tie rods and tie rod nuts to the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement . Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Page 5890 14. Install the steering linkage tie rod. Tighten the steering linkage tie rod nut to 35 Nm (26 lb ft). 15. Install the lower ball joints to the steering knuckles. Refer to Lower Control Arm Replacement . 16. Install the wheel speed sensor wiring harness (2) to the frame on both sides. Install the wiring harness retainers (3) to the frame and the lower control arm. 17. Install the radiator wiring harness (1) to the frame. Install the wiring harness retainers (4) to the frame. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Page 5891 18. Install the lower steering intermediate shaft (1) bolt and tighten to 34 Nm (25 lb ft). 19. Remove the support of the radiator and condenser. 20. Lower the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle . 21. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation . 22. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement . 23. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair). 24. Install the engine splash shields. Refer to Front Compartment Splash Shield Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Splash Shield Replacement). 25. Install the front compartment insulator, if equipped. Refer to Front Compartment Insulator Replacement (See: Body and Frame/Splash Guard/Service and Repair/Front Compartment Insulator Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Service and Repair Front Subframe Mount: Service and Repair Drivetrain and Front Suspension Frame Front Insulator Replacement Special Tools * CH-906-14 - Adapter * CH-906-42 - Adapter * CH-50342 - Threaded Rod For equivalent regional tools. Refer to Special Tools (See: Body and Frame/Frame/Tools and Equipment). Removal Procedure 1. Remove the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement (See: Front Subframe/Service and Repair). 2. Mark installation position of insulator (2) at frame (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Service and Repair > Page 5895 Note: Drilling holes into the insulator rubber to ease removal of the core. 3. Cut out frame insulator core (1) from frame insulator (2). 4. Remove frame insulator core (1) from outer frame insulator (2). 5. Remove the frame insulator (3) from drivetrain and front suspension frame (1) using a chisel (2) or equivalent. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Service and Repair > Page 5896 1. Install the following components on the drivetrain and front suspension frame: * CH-906-14 - Adapter. * CH-906-42 - Adapter. * CH-50342 - Threaded Rod. Note: Check marking of frame insulator. * Align the insulator tab with the alignment marks (1) on the frame. 2. Carefully install the frame insulator in to the front suspension frame. 3. Install the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement (See: Front Subframe/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension Suspension Spring ( Coil / Leaf ): Service and Repair Front Suspension Strut, Strut Component, or Spring Replacement Special Tools * CH 6066 - Strut Spring Compressor * CH 35669 - Wrench For equivalent regional tools, refer to Special Tools (See: Tools and Equipment/Front Suspension) Disassembly Procedure 1. Remove the front suspension strut from the vehicle. Refer to Strut Assembly Replacement (See: Suspension Strut / Shock Absorber/Service and Repair/Front Suspension/Strut Assembly Replacement). 2. Install the front suspension strut (2) in the CH 6066 - compressor (1). Note: The spring is compressed when the strut moves freely. 3. Using the CH 6066 - compressor , compress the front spring. 4. Using a TORX(R) bit (1) and the CH 35669 - wrench (2), remove the front suspension strut nut. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension > Page 5901 5. Remove the front suspension strut (2) from the CH 6066 - compressor. 6. Remove the front suspension strut mount and the front spring from the CH 6066 - compressor. Assembly Procedure 1. Install the front spring and front suspension strut mount (2) to the CH 6066 - compressor (1). 2. Using the CH 6066 - compressor (1), compress the front spring (2). 3. Hand tighten the front suspension strut nut. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension > Page 5902 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Use the proper size TORX(R) bit, hold the strut shaft. 4. Using the CH 35669 - wrench (2) and the TORX(R) bit (1), tighten the front suspension strut nut to 70 Nm (52 lb ft). 5. Remove the front suspension strut from the CH 6066 - compressor. 6. Install the front suspension strut to the vehicle. Refer to Strut Assembly Replacement (See: Suspension Strut / Shock Absorber/Service and Repair/Front Suspension/Strut Assembly Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension > Page 5903 Suspension Spring ( Coil / Leaf ): Service and Repair Rear Suspension Rear Spring Insulator Replacement Rear Spring Insulator Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Support the rear axle with a tall jack stand near the shock absorber. 3. Remove the lower shock absorber bolts. Refer to Shock Absorber Replacement (See: Suspension Strut / Shock Absorber/Service and Repair/Rear Suspension/Shock Absorber Replacement). 4. Using the tall jack stands, slowly lower the rear axle in order to remove tension from the rear springs. 5. Remove the spring (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension > Page 5904 6. Remove the lower and upper rear spring insulators (1, 2). Installation Procedure 1. Install the lower and upper rear spring insulators (1, 2). 2. Install the spring (1) with the spring tag toward the rear of the vehicle, making sure the lower rear is seated into the lower spring seat. 3. Using the jack stands, raise the rear axle in order to compress the rear springs. 4. Install the lower shock absorber bolts. Refer to Shock Absorber Replacement (See: Suspension Strut / Shock Absorber/Service and Repair/Rear Suspension/Shock Absorber Replacement). 5. Lower the vehicle. Rear Spring Replacement Rear Spring Replacement Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension > Page 5905 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Support the rear axle with a tall jack stand near the shock absorber. 3. Remove the lower shock absorber bolts. Refer to Shock Absorber Replacement (See: Suspension Strut / Shock Absorber/Service and Repair/Rear Suspension/Shock Absorber Replacement). 4. Using the tall jack stands, slowly lower the rear axle in order to remove tension from the rear springs. 5. Remove the spring (1). 6. Remove the upper spring seat/jounce bumper (1) from the spring, while leaving the lower spring seat on the axle. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension > Page 5906 1. Install the upper spring seat/jounce bumper (1) on the spring. 2. Install the spring (1) making sure the lower coil is seated into the lower spring seat. 3. Using the jack stands, raise the rear axle in order to compress the rear springs. 4. Install the lower shock absorber bolts. Refer to Shock Absorber Replacement (See: Suspension Strut / Shock Absorber/Service and Repair/Rear Suspension/Shock Absorber Replacement). 5. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Recalls for Suspension Strut / Shock Absorber: > 10381 > Nov > 10 > Campaign - Front Suspension Noise Suspension Strut / Shock Absorber: Recalls Campaign - Front Suspension Noise SERVICE UPDATE Bulletin No.: 10381 Date: November 19, 2010 Subject: 10381 - Service Update for Inventory and Customer Vehicles - Front Suspension Noise Expires with Base Warranty Models: 2011 Chevrolet Cruze This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to lubricate the strut assemblies on certain 2011 model year Chevrolet Cruze vehicles. On these vehicles, contact between the strut's top mount and the splash shield may cause a squeak during normal steering maneuvers at temperatures less than approximately 35°F (2°C). This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should be checked for vehicle eligibility. Important All involved vehicles are identified by VIN in the Global Warranty Management System Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is essential to routinely verify eligibility because not all similar vehicles may be involved regardless of description or option content. Parts Information Parts required to complete this service update are to be obtained locally. CRC Heavy Duty Silicon(TM) Lubricant, P/N 05074 (U.S.), P/N 75074 (Canada) may be purchased through your local automotive supplier. Information about this product may be obtained by calling 1-800-272-8963 (U.S.) or 905-670-2291 (Canada). We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Do not order from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure 1. Raise and support the vehicle until the tires are a few feet off the ground. Refer to Lifting and Jacking the Vehicle in SI. 2. Rotate the steering wheel to the right until it reaches full lock. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Recalls for Suspension Strut / Shock Absorber: > 10381 > Nov > 10 > Campaign - Front Suspension Noise > Page 5915 Note When lubricating the strut, try to lubricate as much of the strut circumference as possible. 3. On the left and right front strut, lubricate the rubber washer (1) and top mount (2) using CRC Heavy Duty Silicone(TM) Lubricant. Using the red straw provided, generously spray the CRC Heavy Duty Silicone lubricant between the top mount and the rubber splash shield. Note Use one hand to bend the straw into position while separating the rubber washer and top mount. Use the other hand to hold the aerosol can and depress the spray nozzle. 4. Rotate the wheel to the left until it reaches full lock and repeat Step 3. Warranty Transaction Information Submit a claim using the table below. * The amount identified in "Net Item" should represent the actual cost of the lubricant needed to perform the required repairs, not to exceed $1.00 USD, $1.02 CAD. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 10381 > Nov > 10 > Campaign - Front Suspension Noise Suspension Strut / Shock Absorber: All Technical Service Bulletins Campaign - Front Suspension Noise SERVICE UPDATE Bulletin No.: 10381 Date: November 19, 2010 Subject: 10381 - Service Update for Inventory and Customer Vehicles - Front Suspension Noise Expires with Base Warranty Models: 2011 Chevrolet Cruze This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to lubricate the strut assemblies on certain 2011 model year Chevrolet Cruze vehicles. On these vehicles, contact between the strut's top mount and the splash shield may cause a squeak during normal steering maneuvers at temperatures less than approximately 35°F (2°C). This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty should be checked for vehicle eligibility. Important All involved vehicles are identified by VIN in the Global Warranty Management System Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is essential to routinely verify eligibility because not all similar vehicles may be involved regardless of description or option content. Parts Information Parts required to complete this service update are to be obtained locally. CRC Heavy Duty Silicon(TM) Lubricant, P/N 05074 (U.S.), P/N 75074 (Canada) may be purchased through your local automotive supplier. Information about this product may be obtained by calling 1-800-272-8963 (U.S.) or 905-670-2291 (Canada). We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Do not order from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure 1. Raise and support the vehicle until the tires are a few feet off the ground. Refer to Lifting and Jacking the Vehicle in SI. 2. Rotate the steering wheel to the right until it reaches full lock. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 10381 > Nov > 10 > Campaign - Front Suspension Noise > Page 5921 Note When lubricating the strut, try to lubricate as much of the strut circumference as possible. 3. On the left and right front strut, lubricate the rubber washer (1) and top mount (2) using CRC Heavy Duty Silicone(TM) Lubricant. Using the red straw provided, generously spray the CRC Heavy Duty Silicone lubricant between the top mount and the rubber splash shield. Note Use one hand to bend the straw into position while separating the rubber washer and top mount. Use the other hand to hold the aerosol can and depress the spray nozzle. 4. Rotate the wheel to the left until it reaches full lock and repeat Step 3. Warranty Transaction Information Submit a claim using the table below. * The amount identified in "Net Item" should represent the actual cost of the lubricant needed to perform the required repairs, not to exceed $1.00 USD, $1.02 CAD. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Suspension Strut / Shock Absorber: Service and Repair Front Suspension Shock Absorber Disposal Shock Absorber Disposal Warning Use the proper eye protection when drilling to prevent metal chips from causing physical injury. 1. Clamp the strut in a vise horizontally with the rod (1) completely extended. 2. Drill a hole in the strut at the center of the end cap (3) using a 5 mm (3/16 in) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the strut. Use shop towels in order to contain the escaping oil. 3. Remove the strut from the vise. 4. Hold the strut over a drain pan vertically with the hole down. 5. Move the rod (1) in and out of the tube (2) to completely drain the oil from the strut. Strut Assembly Replacement Strut Assembly Replacement Special Tools CH 49375 - Wrench For equivalent regional tools, refer to Special Tools (See: Tools and Equipment/Front Suspension). Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 5924 3. Separate the brake hose (1) from the shock absorber. 4. Remove the steering knuckle nuts and bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 5925 5. Remove the stabilizer shaft link nut (1) from the front strut. 6. Lower the vehicle. 7. Open the hood. 8. Remove the upper strut mount nut (1), use the CH 49375 - wrench. 9. Remove the strut mounting plate (2). 10. Separate the front strut from the knuckle. 11. Remove the front strut assembly from the vehicle. 12. For servicing the individual strut components, refer to Strut, Strut Component, or Spring Replacement (See: Suspension Spring ( Coil / Leaf )/Service and Repair/Front Suspension). Installation Procedure 1. Install the front strut assembly. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 5926 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the strut mounting plate (2). 3. Install the upper strut mount nut (1), using the CH 49375 wrench and tighten to 45 Nm (34 lb ft). 4. Insert the front strut in the knuckle. 5. Install the steering knuckle nuts and bolts (1) and tighten to 90 Nm (66 lb ft) +60-70 degrees. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 5927 6. Install the stabilizer shaft link nut (1) and tighten to 65 Nm (48 lb ft). 7. Install the brake hose (1) to the strut. 8. Install the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 9. Lower the vehicle. 10. Check the front end alignment specifications. Refer to Wheel Alignment Specifications (See: Alignment/Specifications/Wheel Alignment Specifications). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 5928 Suspension Strut / Shock Absorber: Service and Repair Rear Suspension Shock Absorber Disposal Shock Absorber Disposal Warning Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Warning To prevent personal injury, wear safety glasses when center punching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the center punch. 1. Make an indentation 10 mm (0.4 in) from the bottom (4) of the tube (3) using a center punch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the center punch (4) using a 5 mm (3/16 in) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a center punch. 5. Drill a second hole in the shock absorber at the center punch (2) using a 5 mm (3/16 in) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Shock Absorber Replacement Shock Absorber Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 5929 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Page 5933 Wheel Bearing: Service and Repair Front Wheel Bearing and Hub Replacement Special Tools EN-45059 - Torque Angle Sensor Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment/Front Suspension). Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the brake rotor. Refer to Front Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Front Brake Rotor Replacement). 3. Remove the wheel speed sensor screw (2). 4. Remove the wheel speed sensor (1) from the steering knuckle. 5. Remove the wheel drive shaft from the front wheel bearing/hub. Refer to Front Wheel Drive Shaft Replacement - Left Side (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Front Wheel Drive Shaft Replacement - Left Side) and/or Front Wheel Drive Shaft Replacement - Right Side (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Front Wheel Drive Shaft Replacement - Right Side). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Page 5934 6. Remove and DISCARD the front wheel bearing/hub bolts (1). 7. Remove the front wheel bearing/hub (1) and front brake shield (2) from the steering knuckle. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Page 5935 1. Position the front brake shield (2) and front wheel bearing/hub (1) assembly in the steering knuckle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the NEW front wheel bearing/hub bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Page 5936 3. Tighten the bearing/hub bolts (1) in 3 passes. Use the EN-45059 - angle meter. * First pass to 90 Nm (66 lb ft) * Second pass to 60° * Third pass to 15° 4. Install the wheel drive shaft at the front wheel bearing/hub. Refer to Front Wheel Drive Shaft Replacement - Left Side (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Front Wheel Drive Shaft Replacement - Left Side) or Front Wheel Drive Shaft Replacement - Right Side (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Front Wheel Drive Shaft Replacement - Right Side). 5. Install the wheel speed sensor (1) to the steering knuckle. 6. Install the wheel speed sensor screw (2) and tighten to 6 Nm (53 lb in). 7. Install the brake rotor. Refer to Front Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Front Brake Rotor Replacement). 8. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Wheel Drive Shaft Nut First Pass......................................................................................................... ............................................................................................150 Nm (111 lb ft) Release....................... .............................................................................................................................................................. ............................................45° Third Pass............................................................................................................................................ .......................................................250 Nm (184 lb ft) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Note: The use of a LOW PROFILE LIFT ARMS SYSTEM may be required to avoid unwanted contact with the vehicle's body and structure depending on lifting equipment used. Refer to the manufacture's recommendation for their applications of low profile lift arms system for their lifting equipment. Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Danger: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle contents. Vehicle Lifting - Frame Contact Lift Front Lift Pads When lifting the vehicle with a frame-contact lift, place the front lift pads on the rocker outer panel weld flange, as shown Rear Lift Pads Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 5945 When lifting the vehicle with a frame-contact lift, place the rear lift pads on the rocker outer panel weld flange, as shown. Vehicle Jacking Caution: When you are jacking the vehicle at the front locations, be certain that the jack or the jack lift pad does not contact the front fascia, front fascia air dam, or the front fenders. If such contact occurs, vehicle damage may result. When jacking at selected front locations additional clearance may be required for the jacking points. Note: When you are lifting a vehicle with a service jack, block the wheels at the opposite end from which you are lifting. Use jack stands to provide additional support. Front of Vehicle When using a service jack under the front of the vehicle use one of the following locations: Place the service jack pad in the same location as shown for the front lift pads. Rear of Vehicle Note: Place jackstands ONLY under strong and stable vehicle structures. Place the service jack pad in the same location as shown for the rear lift pads. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 5956 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any of the following tire pressure sensor components are found to be damage, replace the damaged components. 4. Remove the tire pressure sensor indicator cap and deflate the tire. 5. Remove tire pressure sensor indicator nut (4). Note: When removing the tire pressure sensor, DO NOT re-use the seal, replace with new. 6. Remove the tire pressure sensor seal (3), the washer (2) and the tire pressure sensor (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 5957 1. Clean the area around the mounting point for the tire pressure sensor. 2. Install the washer (2) and the seal (3) on the tire pressure sensor (1). 3. Install the tire pressure sensor (1) on the wheel. 4. Start the nut (4) by hand. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: When installing the tire pressure sensor and the nut, position the tire pressure sensor so that it is parallel to the inside wheel surface while torquing. 5. Install the nut (2) on the tire pressure sensor (1). Tighten the nut (2) to 7 Nm (62 lb in). 6. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 7. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 8. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 5958 9. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Tire Monitoring System/Service and Repair/Tire Pressure Indicator Sensor Learn). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 5964 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 5965 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 5966 Customer TPMS Information Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 5967 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 5968 Frequently Asked Questions Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 5977 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any of the following tire pressure sensor components are found to be damage, replace the damaged components. 4. Remove the tire pressure sensor indicator cap and deflate the tire. 5. Remove tire pressure sensor indicator nut (4). Note: When removing the tire pressure sensor, DO NOT re-use the seal, replace with new. 6. Remove the tire pressure sensor seal (3), the washer (2) and the tire pressure sensor (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 5978 1. Clean the area around the mounting point for the tire pressure sensor. 2. Install the washer (2) and the seal (3) on the tire pressure sensor (1). 3. Install the tire pressure sensor (1) on the wheel. 4. Start the nut (4) by hand. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: When installing the tire pressure sensor and the nut, position the tire pressure sensor so that it is parallel to the inside wheel surface while torquing. 5. Install the nut (2) on the tire pressure sensor (1). Tighten the nut (2) to 7 Nm (62 lb in). 6. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 7. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 8. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 5979 9. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Service and Repair/Tire Pressure Indicator Sensor Learn). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips Tires: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 5984 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 5985 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 5986 Customer TPMS Information Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 5987 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 5988 Frequently Asked Questions Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 5989 Tires: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 5990 Tires: Technical Service Bulletins Wheels/Tires - Use of Nitrogen Gas in Tires INFORMATION Bulletin No.: 05-03-10-020C Date: April 27, 2010 Subject: Use of Nitrogen Gas in Tires Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-03-10-020B (Section 03 - Suspension). GM's Position on the Use of Nitrogen Gas in Tires General Motors does not oppose the use of purified nitrogen as an inflation gas for tires. We expect the theoretical benefits to be reduced in practical use due to the lack of an existing infrastructure to continuously facilitate inflating tires with nearly pure nitrogen. Even occasional inflation with compressed atmospheric air will negate many of the theoretical benefits. Given those theoretical benefits, practical limitations, and the robust design of GM original equipment TPC tires, the realized benefits to our customer of inflating their tires with purified nitrogen are expected to be minimal. The Promise of Nitrogen: Under Controlled Conditions Recently, nitrogen gas (for use in inflating tires) has become available to the general consumer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. The following benefits under controlled conditions are attributed to nitrogen gas and its unique properties: - A reduction in the expected loss of Tire Pressure over time. - A reduction in the variance of Tire Pressures with temperature changes due to reduction of water vapor concentration. - A reduction of long term rubber degradation due to a decrease in oxygen concentrations. Important These are obtainable performance improvements when relatively pure nitrogen gas is used to inflate tires under controlled conditions. The Promise of Nitrogen: Real World Use Nitrogen inflation can provide some benefit by reducing gas migration (pressure loss) at the molecular level through the tire structure. NHTSA (National Highway Traffic Safety Administration) has stated that the inflation pressure loss of tires can be up to 5% a month. Nitrogen molecules are larger than oxygen molecules and, therefore, are less prone to "seeping" through the tire casing. The actual obtainable benefits of nitrogen vary, based on the physical construction and the materials used in the manufacturing of the tire being inflated. Another potential benefit of nitrogen is the reduced oxidation of tire components. Research has demonstrated that oxygen consumed in the oxidation process of the tire primarily comes from the inflation media. Therefore, it is reasonable to assume that oxidation of tire components can be reduced if the tire is inflated with pure nitrogen. However, only very small amounts of oxygen are required to begin the normal oxidation process. Even slight contamination of the tire inflation gas with compressed atmospheric air during normal inflation pressure maintenance, may negate the benefits of using nitrogen. GM Tire Quality, Technology and Focus of Importance Since 1972, General Motors has designed tires under the TPC (Tire Performance Criteria) specification system, which includes specific requirements that ensure robust tire performance under normal usage. General Motors works with tire suppliers to design and manufacture original equipment tires for GM vehicles. The GM TPC addresses required performance with respect to both inflation pressure retention, and endurance properties for original equipment tires. The inflation pressure retention requirements address availability of oxygen and oxidation concerns, while endurance requirements ensure the mechanical structure of the tire has sufficient strength. This combination has provided our customers with tires that maintain their structural integrity throughout their useful treadlife under normal operating conditions. Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Maintaining the correct inflation pressure allows the tire to perform as intended by the vehicle manufacturer in many areas, including comfort, fuel economy, stopping distance, cornering, traction, treadwear, and noise. Since the load carrying capability of a tire is related to inflation pressure, proper inflation pressure maintenance is necessary for the tire to support the load imposed by the vehicle without excessive structural Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 5991 degradation. Important Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 5992 Tires: Technical Service Bulletins Tires/Wheels - Tire Puncture Repair Procedures INFORMATION Bulletin No.: 04-03-10-001F Date: April 27, 2010 Subject: Tire Puncture Repair Procedures For All Cars and Light Duty Trucks Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-001E (Section 03 - Suspension). This bulletin covers puncture repair procedures for passenger car and light duty truck radial tires in the tread area only. The tire manufacturer must be contacted for its individual repair policy and whether or not the speed rating is retained after repair. Caution - Tire changing can be dangerous and should be done by trained professionals using proper tools and procedures. Always read and understand any manufacturer's warnings contained in their customers literature or molded into the tire sidewall. - Serious eye and ear injury may result from not wearing adequate eye and ear protection while repairing tires. - NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads. Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. - NEVER stand, lean or reach over the assembly during inflation. Repairable area on a radial tire. Important - NEVER repair tires worn to the tread indicators 1.59 mm (2/32") remaining depth). - NEVER repair tires with a tread puncture larger than 6.35 mm (1/4"). - NEVER substitute an inner tube for a permissible or non-permissible repair. - NEVER perform an outside-in tire repair (plug only, on the wheel). - Every tire must be removed from the wheel for proper inspection and repair. - Regardless of the type of repair used, the repair must seal the inner liner and fill the injury. - Consult with repair material supplier/manufacturer for repair unit application procedures and repair tools/repair material recommendations. Three basic steps for tire puncture repair: 1. Remove the tire from the wheel for inspection and repair. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 5993 2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent air loss. External Inspection 1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak by using a water and soap solution. Mark the injured area and totally deflate the tire by removing the valve core. 2. Demount the tire from the wheel and place the tire on a well-lighted spreader. Internal Inspection 1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4. Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5. Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4") should not be repaired. Cleaning 1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a scraper. This step serves to remove dirt and mold lubricants to insure proper adhesion and non-contamination of the buffing tool. 2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow guidelines for handling and disposal. Clean the Injury Channel Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 5994 1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to prevent damage to the repair unit. 3. Consult your repair material supplier for recommended reaming tool(s). Fill the Injury 1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent moisture from entering the tire fabric and steel wires. 2. (For combination repair/plug units skip this step.) Cement the injured channel and fill the injury from the inside of the tire with the repair plug per repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just above the inside tire surface. 3. Consult your repair material supplier for proper repair material selection. Repair Unit Selection Important Do not install the repair unit in this step. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 5995 1. Center the repair unit over the injury as a reference and outline an area larger than the unit so that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit selection. Buffing 1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and evenly with a low speed buffing tool using a fine wire brush or gritted rasp. 2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult your repair material supplier for a proper buffing tool. Cementing Apply chemical cement according to the repair material manufacturer's procedures. Repair Unit Application Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 5996 1. The tire must be in the relaxed position when the repair unit is installed (Do not spread the beads excessively). Two-Piece Plug and Repair Units 1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over the injury and stitch down thoroughly with the stitching tool, working from the center out. 3. Being careful not to stretch the plug material, cut the plug flush with the outer tread. Combination Repair/Plug Units 1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2. Follow the repair material manufacturer's recommendations for further installation instructions. 2. Consult your repair material supplier for the proper stitching tool. Safety Cage Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 5997 Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. Final Inspection 1. After remounting and inflating the tire, check both beads, the repair and the valve with a water and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel Assembly Balancing - OFF Vehicle. For additional tire puncture repair information, contact: Rubber Manufacturers Association (RMA) Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tread Wear Indicators Description Tires: Description and Operation Tread Wear Indicators Description Tread Wear Indicators Description The original equipment tires have tread wear indicators that show when you should replace the tires. The location of these indicators are at 60 degree intervals around the outer diameter of the tire. The indicators appear as a 6 mm (0.25 in) wide band when the tire tread depth becomes 1.6 mm (2/32 in). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tread Wear Indicators Description > Page 6000 Tires: Description and Operation Tire Inflation Description Tire Inflation Description This vehicle has been engineered to operate up to the stated load capacity with wheel and tire assemblies of the type, size, construction, and configuration as originally installed. Maintenance of the tire inflation pressures is critical to the continued satisfactory performance, handling, and operating economy of the vehicle. Operation with incorrectly or improperly inflated tires can adversely affect vehicle performance and may contribute to the following: * Reduced fuel economy * Tire overloading * Shortened tire life * Excessive tire wear * Uneven tire wear * Vehicle handling concerns Inspect the tire pressures when the vehicle has not been driven for at least 3 hours or not more than 1.6 km (1 mi) and when the tires are cool to the touch. Tire inflation pressures should be inspected monthly and before an extended trip and adjusted to meet the specifications listed for the particular vehicle. Replace any missing or damaged tire valve stem extensions and/or caps to prevent the intrusion of water and contaminates. One pound per square inch (psi) equals 6.9 kilopascals (kPa). The following table illustrates the conversion of kilopascals to pounds per square inch: For the correct inflation pressures refer to the vehicle's Tire Placard. Tires inflated to a higher than recommended pressure can contribute to the following conditions: * A hard ride * Tire bruising * Rapid tread wear at the center of the tire Tires inflated to a lower than recommended pressure can contribute to the following conditions: * Tire squeal on turns * Hard steering * Rapid and/or uneven wear on the outer edges of the tread * Tire rim bruises and tire rim rupture * Tire cord breakage * High tire temperatures * Sluggish vehicle handling * Higher fuel consumption Unequal pressure on the same axle can cause the following conditions: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tread Wear Indicators Description > Page 6001 * Uneven braking action * Steering lead * Imprecise vehicle handling Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tread Wear Indicators Description > Page 6002 Tires: Description and Operation P-Metric Sized Tires Description P-Metric Sized Tires Description The tire sidewall has a coded marking system, which provides information about the tire. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tread Wear Indicators Description > Page 6003 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures Tires: Procedures Tire Repair Warning * Tire changing can be dangerous and should be done by trained professionals using proper tools and procedures. Always read and understand any manufacturer's warnings contained in their customers literature or molded into the tire sidewall. * Serious eye and ear injury may result from not wearing adequate eye and ear protection while repairing tires. * NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads. * NEVER stand, lean or reach over the assembly during inflation. Note: Repairable area on a radial tire. * NEVER repair tires worn to the tread indicators 1.59 mm (2/32 in) remaining depth. * NEVER repair tires with a tread puncture larger than 6.35 mm (1/4 in). * NEVER substitute an inner tube for a permissible or non-permissible repair. * NEVER perform an outside-in tire repair (plug only, on the wheel). * Every tire must be removed from the wheel for proper inspection and repair. * Regardless of the type of repair used, the repair must seal the inner liner and fill the injury. * Consult with repair material supplier/manufacturer for repair unit application procedures and repair tools/repair material recommendations. Three basic steps for tire puncture repair: 1. Remove the tire from the wheel for inspection and repair. 2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent air loss. External Inspection 1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak by using a water and soap solution. Mark the injured area and totally deflate the tire by removing the valve core. 2. Demount the tire from the wheel and place the tire on a well-lighted spreader. Internal Inspection Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 6006 1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4. Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5. Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4 in) should not be repaired. Cleaning 1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a scraper. This step serves to remove dirt and mold lubricants to insure proper adhesion and non-contamination of the buffing tool. 2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow guidelines for handling and disposal. Clean the Injury Channel Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 6007 1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to prevent damage to the repair unit. 3. Consult your repair material supplier for recommended reaming tool(s). Fill the Injury 1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent moisture from entering the tire fabric and steel wires. 2. For combination repair/plug units skip this step. Cement the injured channel and fill the injury from the inside of the tire with the repair plug per repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just above the inside tire surface. 3. Consult your repair material supplier for proper repair material selection. Repair Unit Selection Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 6008 Note: Do not install the repair unit in this step. 1. Center the repair unit over the injury as a reference and outline an area larger than the unit so that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit selection. Buffing 1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and evenly with a low speed buffing tool using a fine wire brush or gritted rasp. 2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult your repair material supplier for a proper buffing tool. Cementing Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 6009 Apply chemical cement according to the repair material manufacturer's procedures. Repair Unit Application The tire must be in the relaxed position when the repair unit is installed. Do not spread the beads excessively. Two-Piece Plug and Repair Units 1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over the injury and stitch down thoroughly with the stitching tool, working from the center out. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 6010 3. Being careful not to stretch the plug material, cut the plug flush with the outer tread. Combination Repair/Plug Units 1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2. Follow the repair material manufacturer's recommendations for further installation instructions. Consult your repair material supplier for the proper stitching tool. Safety Cage Some run flat tires may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. Final Inspection Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 6011 1. After remounting and inflating the tire, check both beads, the repair and the valve with a water and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off Vehicle (See: Body and Frame/Testing and Inspection/Vibration Diagnosis and Correction/Repair Instructions/Tire and Wheel Assembly Balancing - Off Vehicle). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 6012 Tires: Removal and Replacement Tire Dismounting and Mounting Caution: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. Caution: Damage to either the tire bead or the wheel mounting holes can result from the use of improper wheel attachment or tire mounting procedures. It takes up to 70 seconds for all of the air to completely exhaust from a large tire. Failure to follow the proper procedures could cause the tire changer to put enough force on the tire to bend the wheel at the mounting surface. Such damage may result in vibration and/or shimmy, and under severe usage lead to wheel cracking. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Note: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel, position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Caution: Failure to position valve stem in proper position while dismounting and mounting the tire may result in the TPM sensor to become damaged. 5. Position the wheel and tire so the valve stem is at the 7 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 6013 6. Position the wheel and tire so the valve stem is again at the 7 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM, replace the tire pressure sensor. Refer to Tire Pressure Indicator Sensor Replacement (See: Sensors and Switches - Wheels and Tires/Tire Pressure Sensor/Service and Repair). 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Caution: When mounting the tires, use an approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A silicon base compound can cause the tire to slip on the rim. A corrosive type compound can cause tire or rim deterioration. 9. Apply mounting lubricant to the tire bead and the wheel rim. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Suspension/Specifications/Fluid Type Specifications). 10. Position the rim so the valve stem (1) is at the 7 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 6014 11. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. Ensure that the valve stem (1) is at the 7 o'clock position. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem (1) is at the 7 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 6015 13. Use the tire changer in order to install the tire to the wheel. Warning To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause serious personal injury. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 6024 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 6025 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 6026 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 6031 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 6036 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 6037 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 6038 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 6044 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 6045 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 6046 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 6051 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 6056 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 6057 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 6058 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 6063 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 6068 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 6069 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 6070 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 6076 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 6077 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 6078 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 6083 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 6084 Wheels: Description and Operation Replacement Wheels Description Replace the wheel if any of the following conditions exist: * The wheel exhibits excessive runout. * The wheel is bent. * The wheel is cracked. * The wheel is severely rusted. * The wheel is severely corroded. Note: Air leaks caused by porosity on aluminum wheels are repairable. * The wheel leaks air. Warning If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s), install only new GM original equipment parts. Installation of used parts or non-GM original equipment parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and loss of vehicle control resulting in personal injury. Caution: The use of non-GM original equipment wheels may cause: * Damage to the wheel bearing, the wheel fasteners and the wheel * Tire damage caused by the modified clearance to the adjacent vehicle components * Adverse vehicle steering stability caused by the modified scrub radius * Damage to the vehicle caused by the modified ground clearance * Speedometer and odometer inaccuracy Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of the following conditions exist: * The wheel has elongated bolt holes. * The wheel/nuts, or bolts if applicable, loosen repeatedly. Steel wheel identification is stamped into the wheel near the valve stem. Aluminum wheel identification is cast into the inboard side of the wheel. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 6085 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Guidelines Warning To avoid personal injury when exposed to plastic media blast, hand and/or lathe sanding dust, primer, color coat, and clearcoat, you must work in a properly ventilated area, wearing an approved respirator, eye protection, earplugs and protective gloves and clothing. Evaluating Damage Note: * Inspect the wheel for corrosion, scrapes, gouges, etc. Damage MUST NOT be deeper than what can be sanded or polished off. * Inspect the wheel for cracks. If cracks are found, discard the wheel. * ALL wheels with bent rim flanges must not be repaired or refinished. * The re-machining and the re-clear coating of aluminum wheels is not recommended in the dealer environment due to concerns of repair durability. * Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Aluminum Wheel Refinishing General Recommendations/Options * Painted aluminum wheels use a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. (See option number 1). * If the clearcoat is damaged, it is possible to refinish with clearcoat only, however, the required refinishing process cannot be performed in the dealer environment. Refer to Refinishers Responsibility (Repair option number 2). * Re-plating of chrome-plated aluminum wheels is not recommended. Repair Option Number 1 Material Required/Information Resources * The Paint Manufacturer's Color Book * Refer to the latest GM Approved Refinish Materials Booklet (GM 4901 MD-2005) for specific products for aluminum refinishing. * To access the booklet. Click on GM Collision Parts. Click on GM Technical Repair Information, select Paint Shop. * A Color Compatibility chart is also at this site defining what colors are used on what models. Note: Chemical strippers are not recommended. * Refer to specific Paint Manufacturers for refinish procedures and process pertaining to "Aluminum Refinishing". The procedure requires the wheel surface to be plastic media blasted to remove old paint or clearcoat. General Color Selection * If the wheels being painted were previously clearcoated aluminum, and a painted aluminum look is desired, using Corsican Silver WAEQ9283 for a fine "aluminum-like" look, or Sparkle Silver WA9967 for a very bright look. Body color is another option to the customer that may also be used. * Some specific colors may be recommended on certain models. * If painting wheels that were previously clearcoated aluminum, it is recommended that all 4 wheels and their center caps be refinished to maintain color uniformity. General Refinishing Procedures - Removal 1. Remove the wheels from the vehicle. The tires may remain mounted on the wheels. 2. Remove the balance weights and mark their locations on the tire. 3. Remove excess grease, etc. from the wheels with wax and grease remover. 4. Have the wheels plastic media blasted to remove the clearcoat. Note: MASK OFF ALL MOUNTING SURFACES, whenever a wheel is refinished. The mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. 5. Clean and mask and paint the wheels. General Refinishing Procedures - Installation 1. Unmask the wheels. 2. Clean all wheel mounting surface of any corrosion, overspray, or dirt. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 6086 Note: When re-balancing a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. 3. Install NEW coated balance weights at marked locations. Note: Use a torque stick on an impact wrench, or a torque wrench to consistently and uniformly fasten the wheel to the specified torque for the vehicle. The star pattern must be followed. 4. Install wheels on vehicle. Repair Option Number 2 - Outside Companies * Some outside companies are offering wheel refinishing services. One such company, Transwheel Corporation (800-892-3733), provides this service with GM guidelines. Other companies may also exist. * Any process that re-machines or otherwise remanufactures the wheel should not be used. * The wheel ID must be recorded and follow the wheel throughout the process to assure that the same wheel is returned. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is longer. * Paint and/or clearcoat must not be present on the following surfaces, the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. * A refinishers responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 6090 Wheel Bearing: Service and Repair Front Wheel Bearing and Hub Replacement Special Tools EN-45059 - Torque Angle Sensor Kit For equivalent regional tools, refer to Special Tools (See: Suspension/Tools and Equipment/Front Suspension). Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the brake rotor. Refer to Front Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Front Brake Rotor Replacement). 3. Remove the wheel speed sensor screw (2). 4. Remove the wheel speed sensor (1) from the steering knuckle. 5. Remove the wheel drive shaft from the front wheel bearing/hub. Refer to Front Wheel Drive Shaft Replacement - Left Side (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Front Wheel Drive Shaft Replacement - Left Side) and/or Front Wheel Drive Shaft Replacement - Right Side (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Front Wheel Drive Shaft Replacement - Right Side). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 6091 6. Remove and DISCARD the front wheel bearing/hub bolts (1). 7. Remove the front wheel bearing/hub (1) and front brake shield (2) from the steering knuckle. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 6092 1. Position the front brake shield (2) and front wheel bearing/hub (1) assembly in the steering knuckle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the NEW front wheel bearing/hub bolts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 6093 3. Tighten the bearing/hub bolts (1) in 3 passes. Use the EN-45059 - angle meter. * First pass to 90 Nm (66 lb ft) * Second pass to 60° * Third pass to 15° 4. Install the wheel drive shaft at the front wheel bearing/hub. Refer to Front Wheel Drive Shaft Replacement - Left Side (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Front Wheel Drive Shaft Replacement - Left Side) or Front Wheel Drive Shaft Replacement - Right Side (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Front Wheel Drive Shaft Replacement - Right Side). 5. Install the wheel speed sensor (1) to the steering knuckle. 6. Install the wheel speed sensor screw (2) and tighten to 6 Nm (53 lb in). 7. Install the brake rotor. Refer to Front Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Front Brake Rotor Replacement). 8. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Wheel Drive Shaft Nut First Pass......................................................................................................... ............................................................................................150 Nm (111 lb ft) Release....................... .............................................................................................................................................................. ............................................45° Third Pass............................................................................................................................................ .......................................................250 Nm (184 lb ft) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Nuts........................................................................................................................................... .......................................................140 Nm (103 lb ft) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 6103 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the wheel bearing/hub. Refer to Rear Wheel Bearing and Hub Replacement (Disc Brakes) (See: Wheel Hub/Service and Repair/Rear Suspension). 4. Release the wheel stud (1) from the bearing hub with the hydraulic press and DISCARD the stud. Installation Procedure 1. Install a NEW stud into the bearing/hub assembly (2). Add enough washers (3) in order to draw the stud into the hub. 2. Install and tighten a wheel nut (1) until the head of the wheel stud is fully seated against the back of the bearing/hub flange (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 6104 3. Remove the wheel nut (1) and the washers (3). 4. Install the wheel bearing/hub (2). Refer to Rear Wheel Bearing and Hub Replacement (Disc Brakes) (See: Wheel Hub/Service and Repair/Rear Suspension). 5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Locations Air Conditioning Switch: Locations Component Connector End Views S34 HVAC Controls Switch Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations Air Door Actuator / Motor: Locations Instrument Panel/Center Console Component Views Behind the Left Side of the I/P Components (C67) 1 - M37 Mode Door Actuator 2 - M6L Air Temperature Door Actuator - Left Behind the Left Side of the I/P Components (C68) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 6113 1 - 7D Air Temperature Sensor - Duct Left Lower 2 - M6L Air Temperature Door Actuator - Left 3 M37 Mode Door Actuator 4 - B7H Air Temperature Sensor - Duct Left Upper Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 6114 Air Door Actuator / Motor: Diagrams Component Connector End Views M6 Air Temperature Door Actuator M37 Mode Door Actuator Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 6115 M46 Recirculation Door Motor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 6116 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic Air Door Actuator / Motor: Service and Repair HVAC - Automatic Air Inlet Valve Actuator Gear Replacement (Left Hand Drive) Air Inlet Valve Actuator Gear Replacement (Left Hand Drive) Air Inlet Valve Actuator Replacement Air Inlet Valve Actuator Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6119 Air Inlet Valve and Inside Air Valve Control Cam Replacement (Left Hand Drive) Air Inlet Valve and Inside Air Valve Control Cam Replacement (Left Hand Drive) Removal Procedure 1. Remove instrument panel compartment assembly. Refer to Instrument Panel Compartment Replacement (See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Compartment Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6120 Note: The graphic shows Air Inlet Housing without attaching parts for better clarity. 2. Disconnect electrical connector and remove mode control cam actuator screws (2) and remove mode control cam actuator (1). 3. Remove air inlet valve and inside air valve control cam (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6121 Note: The air inlet valve and inside air valve control cam can only be fitted in one position. 1. Install air inlet valve and inside air valve control cam (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install mode control cam actuator (1) and Install mode control cam actuator screws (2) and connect electrical connector. 2.5 Nm (23 lb in) 3. Install instrument panel compartment assembly. Refer to Instrument Panel Compartment Replacement (See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Compartment Replacement). Mode Control Cam Actuator Replacement Mode Control Cam Actuator Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6122 Mode Control Cam Replacement (Left Hand Drive) Mode Control Cam Replacement (Left Hand Drive) Removal Procedure 1. Remove instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6123 2. Remove instrument panel wiring harness (2) from instrument panel tie bar (1). Disconnect electrical connectors. 3. Remove instrument panel tie bar (2). * Remove 4 instrument panel tie bar bolts (3, 4). * Remove 2 instrument panel tie bar nuts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6124 4. Remove mode control cam (1). Installation Procedure Note: The mode control cam can only be fitted in one position. 1. Install mode control cam (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6125 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install instrument panel tie bar (2). * Install 4 instrument panel tie bar bolts (3, 4) and tighten to 22 Nm (17 lb ft). * Install 2 instrument panel tie bar nuts (1) and tighten to 9 Nm (80 lb in). 3. Install instrument panel wiring harness (2) from instrument panel tie bar (1). Connect electrical connectors. 4. Install instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Mode Valve Gear Replacement (Left Hand Drive) Mode Valve Gear Replacement (Left Hand Drive) Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6126 1. Remove instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). 2. Remove instrument panel wiring harness (2) from instrument panel tie bar (1). Disconnect electrical connectors. 3. Remove instrument panel tie bar (2). * Remove 4 instrument panel tie bar bolts (3, 4). * Remove 2 instrument panel tie bar nuts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6127 4. Remove mode control cam (1). 5. Remove 2 mode valve gear (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6128 1. Install 2 mode valve gear (1). Note: The mode valve gear can only be fitted in one position. The mode valve gears have to be fitted to the according mode valve levers in figured position. The ventilation dampers have to be in middle position. 2. Make sure that mode valve gears of mode valve levers (1) are fitted as shown in graphic above. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6129 Note: The mode control cam can only be fitted in one position. 3. Install mode control cam (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install instrument panel tie bar (2). * Install 4 instrument panel tie bar bolts (3, 4) and tighten to 22 Nm (17 lb ft). * Install 2 instrument panel tie bar nuts (1) and tighten to 9 Nm (80 lb in). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6130 5. Install instrument panel wiring harness (2) from instrument panel tie bar (1). Connect electrical connectors. 6. Install instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Mode Valve Lever Replacement (Left Hand Drive) Mode Valve Lever Replacement (Left Hand Drive) Removal Procedure 1. Remove instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). 2. Remove instrument panel wiring harness (2) from instrument panel tie bar (1). Disconnect electrical connectors. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6131 3. Remove instrument panel tie bar (2). * Remove 4 instrument panel tie bar bolts (3, 4). * Remove 2 instrument panel tie bar nuts (1). 4. Remove mode control cam (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6132 5. Remove 2 mode valve lever (1). Installation Procedure 1. Install 2 mode valve lever (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6133 Note: The mode valve levers have to be fitted to the according mode valve gears in figured position. The ventilation dampers have to be in middle position. 2. Make sure that mode valve gears of mode valve levers (1) are fitted as shown in graphic above. Note: The mode control cam can only be fitted in one position. 3. Install mode control cam (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6134 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 4. Install instrument panel tie bar (2). * Install 4 instrument panel tie bar bolts (3, 4) and tighten to 22 Nm (17 lb ft). * Install 2 instrument panel tie bar nuts (1) and tighten to 9 Nm (80 lb in). 5. Install instrument panel wiring harness (2) from instrument panel tie bar (1). Connect electrical connectors. 6. Install instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Temperature Valve Actuator Replacement Temperature Valve Actuator Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6135 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6136 Air Door Actuator / Motor: Service and Repair HVAC - Manual Air Inlet Valve Actuator Gear Replacement (Left Hand Drive) Air Inlet Valve Actuator Gear Replacement (Left Hand Drive) Air Inlet Valve Actuator Replacement Air Inlet Valve Actuator Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6137 Air Inlet Valve and Inside Air Valve Control Cam Replacement (Left Hand Drive) Air Inlet Valve and Inside Air Valve Control Cam Replacement (Left Hand Drive) Removal Procedure 1. Remove instrument panel compartment assembly. Refer to Instrument Panel Compartment Replacement (See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Compartment Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6138 2. Disconnect electrical connector and remove 3 mode control cam actuator screws (2) and remove mode control cam actuator (1). Note: The graphic shows Air Inlet Housing without attaching parts for better clarity. 3. Remove air inlet valve and inside air valve control cam (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6139 Note: The air inlet valve and inside air valve control cam can only be fitted in one position. 1. Install air inlet valve and inside air valve control cam (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install mode control cam actuator (1) and install 3 mode control cam actuator screws (2) and connect electrical connector. Tighten to 2.5 Nm (23 lb in). 3. Install instrument panel compartment assembly. Refer to Instrument Panel Compartment Replacement (See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Compartment Replacement). Mode Control Cam Replacement (Left Hand Drive) Mode Control Cam Replacement (Left Hand Drive) Removal Procedure 1. Remove the instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6140 Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement) 2. Remove the instrument panel wiring harness (2) from the instrument panel tie bar (1). Disconnect the electrical connectors. 3. Remove the instrument panel tie bar (2). * Remove the 4 instrument panel tie bar bolts (3, 4). * Remove the 2 instrument panel tie bar nuts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6141 4. Remove the mode control cam (1). Installation Procedure Note: The mode control cam can only be fitted in one position. 1. Install the mode control cam (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6142 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 2. Install the instrument panel tie bar (2). * Install the 4 instrument panel tie bar bolts (3, 4) and tighten to 19 Nm(17 lb ft) . * Install the 2 instrument panel tie bar nuts (1) and tighten to 9 Nm(80 lb in) . 3. Install the instrument panel wiring harness (2) from the instrument panel tie bar (1). Connect the electrical connectors. 4. Install the instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Mode Valve Gear Replacement (Left Hand Drive) Mode Valve Gear Replacement (Left Hand Drive) Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6143 1. Remove instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). 2. Remove instrument panel wiring harness (2) from instrument panel tie bar (1). Disconnect electrical connectors. 3. Remove instrument panel tie bar (2). * Remove 4 instrument panel tie bar bolts (3, 4). * Remove 2 instrument panel tie bar nuts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6144 4. Remove mode control cam (1). 5. Remove 2 mode valve gear (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6145 1. Install 2 mode valve gear (1). Note: The mode valve gear can only be fitted in one position. The mode valve gears have to be fitted to the according mode valve levers in figured position. The ventilation dampers have to be in middle position. 2. Make sure that mode valve gears of mode valve levers (1) are fitted as shown in graphic above. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6146 Note: The mode control cam can only be fitted in one position. 3. Install mode control cam (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install instrument panel tie bar (2). * Install 4 instrument panel tie bar bolts (3, 4) and tighten to 22 Nm (17 lb ft). * Install 2 instrument panel tie bar nuts (1) and tighten to 9 Nm (80 lb in). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6147 5. Install instrument panel wiring harness (2) from instrument panel tie bar (1). Connect electrical connectors. 6. Install instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Mode Valve Lever Replacement (Left Hand Drive) Mode Valve Lever Replacement (Left Hand Drive) Removal Procedure 1. Remove instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). 2. Remove instrument panel wiring harness (2) from instrument panel tie bar (1). Disconnect electrical connectors. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6148 3. Remove instrument panel tie bar (2). * Remove 4 instrument panel tie bar bolts (3, 4). * Remove 2 instrument panel tie bar nuts (1). 4. Remove mode control cam (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6149 5. Remove 2 mode valve lever (1). Installation Procedure 1. Remove 2 mode valve lever (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6150 Note: The mode valve levers have to be fitted to the according mode valve gears in figured position. The ventilation dampers have to be in middle position. 2. Make sure that mode valve gears of mode valve levers (1) are fitted as shown in graphic above. Note: The mode control cam can only be fitted in one position. 3. Install mode control cam (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6151 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install instrument panel tie bar (2). * Install 4 instrument panel tie bar bolts (3, 4) and tighten to 22 Nm (17 lb ft). * Install 2 instrument panel tie bar nuts (1) and tighten to 9 Nm (80 lb in). 5. Install instrument panel wiring harness (2) from instrument panel tie bar (1). Connect electrical connectors. 6. Install instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Temperature Valve Actuator Replacement Temperature Valve Actuator Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6152 Vent Valve Lever Replacement (Left Hand Drive) Vent Valve Lever Replacement (Left Hand Drive) Removal Procedure 1. Remove instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6153 2. Disconnect electrical connector and remove 3 mode control cam actuator screws (2) and remove mode control cam actuator (1). Note: The graphic shows air inlet housing without attaching parts for better clarity. 3. Remove air inlet valve and inside air valve control cam (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6154 4. Remove 2 vent valve levers (1). Installation Procedure 1. Install 2 vent valve levers (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6155 Note: The vent valve levers have to be fitted to the according vent valve gears in figured position. The air circulation dampers have to be in middle position. 2. Make sure that mode valve gears of vent valve levers (1) are fitted as shown in graphic above. Note: The air inlet valve and inside air valve control cam can only be fitted in one position. 3. Install air inlet valve and inside air valve control cam (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6156 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install mode control cam actuator (1) and Install 3 mode control cam actuator screws (2) and connect electrical connector. 2.5 Nm (23 lb in) 5. Install instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Inlet Housing Replacement Air Duct: Service and Repair Air Inlet Housing Replacement Air Inlet Housing Replacement Removal Procedure 1. Remove heater and air conditioning evaporator and blower module. Refer to Heater and Air Conditioning Evaporator Case Replacement (See: Evaporator Case/Service and Repair). 2. Remove air inlet housing (2) from heater and air conditioning evaporator and blower module (1). * Disconnect electrical connectors. * Remove 4 air inlet housing bolts (3). 3. Remove air inlet valve actuator. Refer to Air Inlet Valve Actuator Replacement (See: Air Door/Air Door Actuator / Motor/Service and Repair/HVAC - Automatic/Air Inlet Valve Actuator Replacement). 4. Remove air inlet valve and inside air valve control cam. Refer to Air Inlet Valve and Inside Air Valve Control Cam Replacement (Left Hand Drive) (See: Air Door/Air Door Actuator / Motor/Service and Repair/HVAC - Automatic/Air Inlet Valve and Inside Air Valve Control Cam Replacement (Left Hand Drive)). Installation Procedure 1. Install air inlet valve and inside air valve control cam. Refer to Air Inlet Valve and Inside Air Valve Control Cam Replacement (Left Hand Drive) (See: Air Door/Air Door Actuator / Motor/Service and Repair/HVAC - Automatic/Air Inlet Valve and Inside Air Valve Control Cam Replacement (Left Hand Drive)). 2. Install air inlet valve actuator. Refer to Air Inlet Valve Actuator Replacement (See: Air Door/Air Door Actuator / Motor/Service and Repair/HVAC - Automatic/Air Inlet Valve Actuator Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Inlet Housing Replacement > Page 6161 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install air inlet housing (2) to heater and air conditioning evaporator and blower module (1). * Connect electrical connectors. * Install 4 air inlet housing bolts (3) and tighten to 2.5 Nm (22 lb in). 4. Install heater and air conditioning evaporator and blower module. Refer to Heater and Air Conditioning Evaporator Case Replacement (See: Evaporator Case/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Inlet Housing Replacement > Page 6162 Air Duct: Service and Repair Floor Air Outlet Duct Replacement - Left Side (Left Hand Drive) Floor Air Outlet Duct Replacement - Left Side (Left Hand Drive) Removal Procedure 1. Remove instrument outer trim cover - left side. Refer to Instrument Panel Outer Trim Cover Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Outer Trim Cover Replacement - Left Side). 2. Remove instrument panel lower trim pad cover - left side. Refer to Instrument Panel Lower Trim Pad Cover Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Trim Pad Cover Replacement). 3. Remove floor air outlet duct (1) - left side. Installation Procedure 1. Install floor air outlet duct (1) - left side. 2. Install instrument panel lower trim pad cover - left side. Refer to Instrument Panel Lower Trim Pad Cover Replacement (See: Body and Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Inlet Housing Replacement > Page 6163 Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Trim Pad Cover Replacement). 3. Install instrument outer trim cover - left side. Refer to Instrument Panel Outer Trim Cover Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Outer Trim Cover Replacement - Left Side). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Inlet Housing Replacement > Page 6164 Air Duct: Service and Repair Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive) Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Inlet Housing Replacement > Page 6165 Air Duct: Service and Repair Floor Front Air Outlet Duct Adapter Replacement Floor Front Air Outlet Duct Adapter Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Inlet Housing Replacement > Page 6166 Air Duct: Service and Repair Air Inlet Housing Replacement Air Inlet Housing Replacement Removal Procedure 1. Remove heater and air conditioning evaporator and blower module. Refer to Heater and Air Conditioning Evaporator Case Replacement (See: Evaporator Case/Service and Repair). 2. Remove air inlet housing (2) from heater and air conditioning evaporator and blower module (1). * Disconnect electrical connectors. * Remove 4 air inlet housing bolts (3). 3. Remove air inlet valve actuator. Refer to Air Inlet Valve Actuator Replacement (See: Air Door/Air Door Actuator / Motor/Service and Repair/HVAC - Automatic/Air Inlet Valve Actuator Replacement). 4. Remove air inlet valve and inside air valve control cam. Refer to Air Inlet Valve and Inside Air Valve Control Cam Replacement (Left Hand Drive) (See: Air Door/Air Door Actuator / Motor/Service and Repair/HVAC - Automatic/Air Inlet Valve and Inside Air Valve Control Cam Replacement (Left Hand Drive)). Installation Procedure 1. Install air inlet valve and inside air valve control cam. Refer to Air Inlet Valve and Inside Air Valve Control Cam Replacement (Left Hand Drive) (See: Air Door/Air Door Actuator / Motor/Service and Repair/HVAC - Automatic/Air Inlet Valve and Inside Air Valve Control Cam Replacement (Left Hand Drive)). 2. Install air inlet valve actuator. Refer to Air Inlet Valve Actuator Replacement (See: Air Door/Air Door Actuator / Motor/Service and Repair/HVAC - Automatic/Air Inlet Valve Actuator Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Inlet Housing Replacement > Page 6167 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install air inlet housing (2) to heater and air conditioning evaporator and blower module (1). * Connect electrical connectors. * Install 4 air inlet housing bolts (3) and tighten to 2.5 Nm (22 lb in). 4. Install heater and air conditioning evaporator and blower module. Refer to Heater and Air Conditioning Evaporator Case Replacement (See: Evaporator Case/Service and Repair). Floor Air Outlet Duct Replacement - Left Side (Left Hand Drive) Floor Air Outlet Duct Replacement - Left Side (Left Hand Drive) Removal Procedure 1. Remove instrument outer trim cover - left side. Refer to Instrument Panel Outer Trim Cover Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Outer Trim Cover Replacement - Left Side). 2. Remove instrument panel lower trim pad cover - left side. Refer to Instrument Panel Lower Trim Pad Cover Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Trim Pad Cover Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Inlet Housing Replacement > Page 6168 3. Remove floor air outlet duct (1) - left side. Installation Procedure 1. Install floor air outlet duct (1) - left side. 2. Install instrument panel lower trim pad cover - left side. Refer to Instrument Panel Lower Trim Pad Cover Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Trim Pad Cover Replacement). 3. Install instrument outer trim cover - left side. Refer to Instrument Panel Outer Trim Cover Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Outer Trim Cover Replacement - Left Side). Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive) Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Inlet Housing Replacement > Page 6169 Floor Front Air Outlet Duct Adapter Replacement Floor Front Air Outlet Duct Adapter Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Inlet Housing Replacement > Page 6170 Floor Rear Air Outlet Duct Replacement - Left Side Floor Rear Air Outlet Duct Replacement - Left Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Inlet Housing Replacement > Page 6171 Floor Rear Air Outlet Duct Replacement - Right Side Floor Rear Air Outlet Duct Replacement - Right Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Inlet Housing Replacement > Page 6172 Front Side Door Air Outlet Replacement Front Side Door Air Outlet Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Inlet Housing Replacement > Page 6173 Radio Cooling Duct Replacement (Left Hand Drive) Radio Cooling Duct Replacement (Left Hand Drive) Removal Procedure 1. Remove instrument panel lower trim panel - left side. Refer to Instrument Panel Lower Trim Panel Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Trim Panel Replacement - Left Side). 2. Remove instrument outer trim cover - left side. Refer to Instrument Panel Outer Trim Cover Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Outer Trim Cover Replacement - Left Side). 3. Remove instrument panel lower trim pad cover - left side. Refer to Instrument Panel Lower Trim Pad Cover Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Trim Pad Cover Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Inlet Housing Replacement > Page 6174 4. Remove radio cooling duct (1). Installation Procedure 1. Install radio cooling duct (1). 2. Install instrument panel lower trim pad cover - left side. Refer to Instrument Panel Lower Trim Pad Cover Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Trim Pad Cover Replacement). 3. Install instrument outer trim cover - left side. Refer to Instrument Panel Outer Trim Cover Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Outer Trim Cover Replacement - Left Side). 4. Install instrument panel lower trim panel - left side. Refer to Instrument Panel Lower Trim Panel Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Trim Panel Replacement - Left Side). Windshield Defroster Nozzle Replacement Windshield Defroster Nozzle Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Inlet Housing Replacement > Page 6175 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Body Air Outlet Deflector Replacement (Notchback) Air Register: Service and Repair Body Air Outlet Deflector Replacement (Notchback) Body Air Outlet Deflector Replacement (Notchback) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Body Air Outlet Deflector Replacement (Notchback) > Page 6180 Air Register: Service and Repair Floor Air Outlet Replacement Floor Air Outlet Replacement Removal Procedure 1. Remove the instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). 2. Remove the instrument panel wiring harness (2) from the instrument panel tie bar (1). Disconnect the electrical connectors. 3. Remove the instrument panel tie bar (2). * Remove the 4 instrument panel tie bar bolts (3, 4). * Remove the 2 instrument panel tie bar nuts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Body Air Outlet Deflector Replacement (Notchback) > Page 6181 4. Remove the heater wiring harness. 5. Remove the floor air outlet (2). Remove the 6 floor air outlet bolts (1). Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the floor air outlet (2). Install the 6 floor air outlet bolts (1) and tighten to 2.5 Nm (23 lb in). 2. Install the heater wiring harness. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Body Air Outlet Deflector Replacement (Notchback) > Page 6182 3. Install the instrument panel tie bar (2). * Install the 4 instrument panel tie bar bolts (3, 4) and tighten to 22 Nm (17 lb ft). * Install the 2 instrument panel tie bar nuts (1) and tighten to 9 Nm (80 lb in). 4. Attach the instrument panel wiring harness (2) to the instrument panel tie bar (1). Connect the electrical connectors. 5. Install the instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Body Air Outlet Deflector Replacement (Notchback) > Page 6183 Air Register: Service and Repair Instrument Panel Outer Air Outlet Duct Replacement Instrument Panel Outer Air Outlet Duct Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Body Air Outlet Deflector Replacement (Notchback) > Page 6184 Air Register: Service and Repair Instrument Panel Outer Air Outlet Replacement - Left Side Instrument Panel Outer Air Outlet Replacement - Left Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Body Air Outlet Deflector Replacement (Notchback) > Page 6185 Air Register: Service and Repair Body Air Outlet Deflector Replacement (Notchback) Body Air Outlet Deflector Replacement (Notchback) Floor Air Outlet Replacement Floor Air Outlet Replacement Removal Procedure 1. Remove the instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Body Air Outlet Deflector Replacement (Notchback) > Page 6186 2. Remove the instrument panel wiring harness (2) from the instrument panel tie bar (1). Disconnect the electrical connectors. 3. Remove the instrument panel tie bar (2). * Remove the 4 instrument panel tie bar bolts (3, 4). * Remove the 2 instrument panel tie bar nuts (1). 4. Remove the heater wiring harness. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Body Air Outlet Deflector Replacement (Notchback) > Page 6187 5. Remove the floor air outlet (2). Remove the 6 floor air outlet bolts (1). Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the floor air outlet (2). Install the 6 floor air outlet bolts (1) and tighten to 2.5 Nm (23 lb in). 2. Install the heater wiring harness. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Body Air Outlet Deflector Replacement (Notchback) > Page 6188 3. Install the instrument panel tie bar (2). * Install the 4 instrument panel tie bar bolts (3, 4) and tighten to 22 Nm (17 lb ft). * Install the 2 instrument panel tie bar nuts (1) and tighten to 9 Nm (80 lb in). 4. Attach the instrument panel wiring harness (2) to the instrument panel tie bar (1). Connect the electrical connectors. 5. Install the instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Instrument Panel Outer Air Outlet Duct Replacement Instrument Panel Outer Air Outlet Duct Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Body Air Outlet Deflector Replacement (Notchback) > Page 6189 Instrument Panel Outer Air Outlet Replacement - Left Side Instrument Panel Outer Air Outlet Replacement - Left Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Body Air Outlet Deflector Replacement (Notchback) > Page 6190 Instrument Panel Center Air Outlet Replacement Instrument Panel Center Air Outlet Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Body Air Outlet Deflector Replacement (Notchback) > Page 6191 Instrument Panel Outer Air Outlet Replacement - Right Side Instrument Panel Outer Air Outlet Replacement - Right Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Body Air Outlet Deflector Replacement (Notchback) > Page 6192 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications Ambient Temperature Sensor / Switch HVAC: Specifications Ambient Air Temperature Sensor Resistance Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views Ambient Temperature Sensor / Switch HVAC: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components 2 of 2 1 - B108 Air Quality Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6198 Ambient Temperature Sensor / Switch HVAC: Locations Wheels/Vehicle Underbody Component Views Wheels/Vehicle Underbody Component Views Left Front Frame and Underbody Components 2 of 2 1 - B9 Air Temperature Sensor - Ambient Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6199 Ambient Temperature Sensor / Switch HVAC: Diagrams Component Connector End Views B9 Air Temperature Sensor - Ambient Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6200 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Quality Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations Blower Motor: Locations Instrument Panel/Center Console Component Views Behind the Center of the I/P Components (C68) 1 - X212 Instrument Panel Harness and HVAC Haness 2 - X3 HVAC Control Module X3 3 - K33 HVAC Control Module 4 - X2 Blower Motor Control Module X2 5 - K8 Blower Motor Control Module 6 - M8 Blower Motor 7 - X1 Blower Motor Control Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 6204 Blower Motor: Diagrams Component Connector End Views M8 Blower Motor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 6205 Blower Motor: Service and Repair Blower Motor Replacement (Left Hand Drive) Removal Procedure 1. Remove the right floor air outlet duct. Refer to Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive) (See: Air Duct/Service and Repair/Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive)). 2. Remove the blower motor wire harness connector. 3. Remove the blower motor cup bolts (1). 4. Remove the blower motor cup from the blower motor (2). 5. Remove the blower motor bolts (1). 6. Remove the blower motor (2) from the heater case. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 6206 1. Install the new blower motor (2) to the heater case. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 2. Install the blower motor bolts (1) and tighten to 4.5 Nm (40 lb in). 3. Install the motor blower cup to the blower motor. 4. Install the blower motor cup bolts and tighten to 2.5 Nm (23 lb in). 5. Install the blower motor wire harness connector. 6. Install the right floor air outlet duct. Refer to Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive) (See: Air Duct/Service and Repair/Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive)). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair > Passenger Compartment Air Filter Replacement Cabin Air Filter: Service and Repair Passenger Compartment Air Filter Replacement Passenger Compartment Air Filter Replacement Removal Procedure 1. Remove instrument panel outer trim cover. Refer to Instrument Panel Outer Trim Cover Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Outer Trim Cover Replacement - Right Side). 2. Remove instrument panel compartment. Refer to Instrument Panel Compartment Replacement (See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Compartment Replacement). 3. Unclip 2 clips (1) and remove passenger compartment air filter (2). Installation Procedure 1. Install passenger compartment air filter (2) and clip in 2 clips (1). 2. Install instrument panel compartment. Refer to Instrument Panel Compartment Replacement (See: Body and Frame/Interior Moulding / Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair > Passenger Compartment Air Filter Replacement > Page 6211 Trim/Glove Compartment/Service and Repair/Instrument Panel Compartment Replacement). 3. Install instrument panel outer trim cover. Refer to Instrument Panel Outer Trim Cover Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Outer Trim Cover Replacement - Right Side). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair > Passenger Compartment Air Filter Replacement > Page 6212 Cabin Air Filter: Service and Repair Service Manual Procedures Passenger Compartment Air Filter Replacement Removal Procedure 1. Remove instrument panel outer trim cover. 2. Remove instrument panel compartment. 3. Unclip 2 clips (1) and remove passenger compartment air filter (2). Installation Procedure 1. Install passenger compartment air filter (2) and clip in 2 clips (1). 3. Install instrument panel outer trim cover. 2. Install instrument panel compartment. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations Cabin Temperature Sensor / Switch: Locations Instrument Panel/Center Console Component Views Behind the Left Side of the I/P Components (C68) 1 - 7D Air Temperature Sensor - Duct Left Lower 2 - M6L Air Temperature Door Actuator - Left 3 M37 Mode Door Actuator 4 - B7H Air Temperature Sensor - Duct Left Upper Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Inside Air Temperature Sensor Replacement (Left Hand Drive) Cabin Temperature Sensor / Switch: Service and Repair Inside Air Temperature Sensor Replacement (Left Hand Drive) Inside Air Temperature Sensor Replacement (Left Hand Drive) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Inside Air Temperature Sensor Replacement (Left Hand Drive) > Page 6218 Cabin Temperature Sensor / Switch: Service and Repair Inside Air Moisture and Windshield Temperature Sensor Replacement Inside Air Moisture and Windshield Temperature Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Climate Control Exhaust Gas Sensor > Component Information > Diagrams Climate Control Exhaust Gas Sensor: Diagrams Component Connector End Views B108 Air Quality Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair Compressor Clutch: Service and Repair Air Conditioning Clutch Assembly Replacement Special Tools GE-806 - Holding Wrench For equivalent regional tools, refer to Special Tools (See: Tools and Equipment/Heating, Ventilation, and Air Conditioning). Removal Procedure 1. Remove the compressor. Refer to Air Conditioning Compressor Replacement (1.4L LUJ) (See: Service and Repair/Removal and Replacement/Air Conditioning Compressor Replacement)Air Conditioning Compressor Replacement (1.8L LUW) (See: Service and Repair/Removal and Replacement/Air Conditioning Compressor Replacement). Note: Clamp the compressor to bracket in a vise, using protective jaws. 2. Clamp the compressor in a vise. 3. Remove the compressor clutch plate. * Remove the bolt. * Counterhold with GE-806 - holding wrench (1). Note: Re-use spacer washers when refitting. 4. Remove the spacer washers. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Page 6226 5. Remove the retaining ring (1) from belt pulley. 6. Pull off the compressor pulley (2). Installation Procedure 1. Install the compressor pulley on the compressor housing. 2. Install the retaining ring in the groove in the compressor housing. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Page 6227 3. Install the compressor clutch plate. Insert the spacing washer (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the compressor clutch plate bolt to 13.5 Nm (119 lb in). Counterhold with GE-806 holding wrench (1). Note: Check reference gap between clutch plate and the belt pulley at 4 points with feeler gauge and form mean value. 5. Inspect reference gap of compressor clutch. Reference value: 0.3 mm - 0.6 mm (0.012 in - 0.024 in ). Note: If the reference gap is too large, install thicker spacing washer (2) between compressor shaft and clutch, install a thinner one if the reference gap is too small. Spacing washers available: 0.1 mm, 0.3 mm, 0.5 mm. 6. Correct the reference gap for the compressor clutch. Detach the compressor clutch plate and change spacing washer. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Page 6228 7. Repeat inspection as described. 8. Remove the compressor from the vise. 9. Install the compressor. Refer to Air Conditioning Compressor Replacement (1.4L LUJ) (See: Service and Repair/Removal and Replacement/Air Conditioning Compressor Replacement)Air Conditioning Compressor Replacement (1.8L LUW) (See: Service and Repair/Removal and Replacement/Air Conditioning Compressor Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 6232 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 6233 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 6234 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair Condenser HVAC: Service and Repair Air Conditioning Condenser Replacement Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Procedures/Refrigerant Recovery and Recharging). 2. Remove front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 3. Remove headlamps. Refer to Headlamp Replacement (See: Lighting and Horns/Headlamp/Service and Repair). 4. Remove air intake duct (1). 5. Remove air conditioning compressor and condenser hose from condenser. Refer to Air Conditioning Compressor and Condenser Hose Replacement (1.4L LUJ) (See: Compressor HVAC/Service and Repair/Removal and Replacement/Air Conditioning Compressor and Condenser Hose Replacement)Air Conditioning Compressor and Condenser Hose Replacement (1.8L LUW) (See: Compressor HVAC/Service and Repair/Removal and Replacement/Air Conditioning Compressor and Condenser Hose Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Page 6238 6. Remove air conditioning condenser hose bolt and air conditioning condenser hose (1, 2). 7. Remove air conditioning refrigerant pressure sensor. Refer to Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (See: Refrigerant Pressure Sensor / Switch/Service and Repair). 8. Remove air conditioning condenser (1). Installation Procedure 1. Install air conditioning condenser (1). 2. Install air conditioning refrigerant pressure sensor. Refer to Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (See: Refrigerant Pressure Sensor / Switch/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Page 6239 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install air conditioning condenser hose (1, 2) and air conditioning condenser hose bolt and tighten to 19 Nm (14 lb ft). 4. Install air conditioning compressor and condenser hose to air conditioning condenser. Refer to Air Conditioning Compressor and Condenser Hose Replacement (1.4L LUJ) (See: Compressor HVAC/Service and Repair/Removal and Replacement/Air Conditioning Compressor and Condenser Hose Replacement)Air Conditioning Compressor and Condenser Hose Replacement (1.8L LUW) (See: Compressor HVAC/Service and Repair/Removal and Replacement/Air Conditioning Compressor and Condenser Hose Replacement). 5. Install air intake duct (1). 6. Install headlamps. Refer to Headlamp Replacement (See: Lighting and Horns/Headlamp/Service and Repair). 7. Install front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 8. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Procedures/Refrigerant Recovery and Recharging). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations Control Assembly: Locations Instrument Panel/Center Console Component Views Behind the Center of the I/P Components (C68) 1 - X212 Instrument Panel Harness and HVAC Haness 2 - X3 HVAC Control Module X3 3 - K33 HVAC Control Module 4 - X2 Blower Motor Control Module X2 5 - K8 Blower Motor Control Module 6 - M8 Blower Motor 7 - X1 Blower Motor Control Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 6243 Control Assembly: Diagrams Component Connector End Views K33 HVAC Control Module X1 K33 HVAC Control Module X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 6244 K33 HVAC Control Module X3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 6245 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > HVAC - Automatic Control Assembly: Service and Repair HVAC - Automatic Heater and Air Conditioning Control Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6248 Control Assembly: Service and Repair HVAC - Manual Heater and Air Conditioning Control Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations Control Module HVAC: Locations Instrument Panel/Center Console Component Views Behind the Center of the I/P Components (C68) 1 - X212 Instrument Panel Harness and HVAC Haness 2 - X3 HVAC Control Module X3 3 - K33 HVAC Control Module 4 - X2 Blower Motor Control Module X2 5 - K8 Blower Motor Control Module 6 - M8 Blower Motor 7 - X1 Blower Motor Control Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Page 6252 Control Module HVAC: Diagrams Component Connector End Views K8 Blower Motor Control Module X1 K8 Blower Motor Control Module X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Page 6253 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic Control Module HVAC: Service and Repair HVAC - Automatic Heater and Blower and Air Conditioning Control Module Replacement (Left Hand Drive) Removal Procedure 1. Remove instrument panel compartment. Refer to Instrument Panel Compartment Replacement (See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Compartment Replacement). 2. Remove floor air outlet duct right side. Refer to Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive) (See: Air Duct/Service and Repair/Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive)). 3. Remove the 2 heater and blower and air conditioning control module bolts (1) and the heater and blower and air conditioning control module wiring harness plug (2). 4. Remove heater and blower and air conditioning control module (3). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6256 1. Install heater and blower and air conditioning control module (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the heater and blower and air conditioning control module wiring harness plug (2) and the 2 heater and blower and air conditioning control module bolts (1). Tighten to 2.5 Nm (23 lb in). 3. Install floor air outlet duct - right side. Refer to Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive) (See: Air Duct/Service and Repair/Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive)). 4. Install instrument panel compartment. Refer to Instrument Panel Compartment Replacement (See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Compartment Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6257 Control Module HVAC: Service and Repair HVAC - Manual Heater and Blower and Air Conditioning Control Module Replacement (Left Hand Drive) Removal Procedure 1. Remove instrument panel compartment. Refer to Instrument Panel Compartment Replacement (See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Compartment Replacement). 2. Remove floor air outlet duct right side. Refer to Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive) (See: Air Duct/Service and Repair/Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive)). 3. Remove the 2 heater and blower and air conditioning control module bolts (1) and the heater and blower and air conditioning control module wiring harness plug (2). 4. Remove heater and blower control module (3). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6258 1. Install heater and blower control module (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the heater and blower and air conditioning control module wiring harness plug (2) and the 2 heater and blower and air conditioning control module bolts (1). Tighten to 2.5 Nm (22 lb in). 3. Install floor air outlet duct right side. Refer to Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive) (See: Air Duct/Service and Repair/Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive)). 4. Install instrument panel compartment. Refer to Instrument Panel Compartment Replacement (See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Compartment Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > Air Conditioning System Seal Replacement A/C Coupler O-ring: Service and Repair Air Conditioning System Seal Replacement Air Conditioning System Seal Replacement Removal Procedure 1. Remove the seal washer from the A/C refrigerant component. Note: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 2. Inspect the seal washer for signs of damage to help determine the root cause of the failure. 3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. Note: DO NOT reuse sealing washer. 4. Discard the sealing washer. Installation Procedure Note: Flat washer type seals do not require lubrication. 1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components. 4. Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting. Note: After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the A/C line and the A/C component. 5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > Air Conditioning System Seal Replacement > Page 6264 A/C Coupler O-ring: Service and Repair Air Conditioning O-Ring Seal Replacement Air Conditioning O-Ring Seal Replacement Removal Procedure 1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure. 2. Remove the O-ring seal from the A/C refrigerant component. 3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure. 4. Inspect the A/C components for damage or burrs. Repair if necessary. Note: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 5. Cap or tape the A/C refrigerant components. 6. Discard the O-ring seal. Installation Procedure 1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components. Note: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system. 4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. Note: DO NOT reuse O-ring seals. 5. Carefully slide the new O-ring seal onto the A/C refrigerant component. 6. The O-ring (1) seal must be fully seated. 7. Assemble the A/C components. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair Evaporator Case: Service and Repair Heater and Air Conditioning Evaporator Case Replacement Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Procedures/Refrigerant Recovery and Recharging). 2. Drain the cooling system. Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). 3. Remove instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). 4. Remove instrument panel wiring harness (2) from instrument panel tie bar (1). Disconnect electrical connectors. 5. Remove instrument panel tie bar (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 6268 1. Remove 4 instrument panel tie bar bolts (3, 4). 2. Remove 2 instrument panel tie bar nuts (1). 6. Remove air conditioning module wiring harness (1). Disconnect electrical connectors. 7. Remove heater core. Refer to Heater Core Replacement (See: Heater Core/Service and Repair). 8. Remove blower motor. Refer to Blower Motor Replacement (Left Hand Drive) (See: Blower Motor/Service and Repair). 9. Remove heater and blower and air conditioning control module. Refer to Heater and Blower and Air Conditioning Control Module Replacement (Left Hand Drive) (See: Control Module HVAC/Service and Repair/HVAC - Automatic) or Heater and Blower and Air Conditioning Control Module Replacement (Left Hand Drive) (See: Control Module HVAC/Service and Repair/HVAC - Manual). 10. Remove heater and air conditioning evaporator case (2) from heater and blower and air conditioning control module (1). 11. Remove 10 heater and air conditioning evaporator case bolts (3). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 6269 1. Install heater and air conditioning evaporator case (2) to heater and blower and air conditioning control module (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install 10 heater and air conditioning evaporator case bolts (3) and tighten to 2.5 Nm (23 lb in). 3. Install heater and blower and air conditioning control module. Refer to Heater and Blower and Air Conditioning Control Module Replacement (Left Hand Drive) (See: Control Module HVAC/Service and Repair/HVAC - Automatic) or Heater and Blower and Air Conditioning Control Module Replacement (Left Hand Drive) (See: Control Module HVAC/Service and Repair/HVAC - Manual). 4. Install blower motor. Refer to Blower Motor Replacement (Left Hand Drive) (See: Blower Motor/Service and Repair). 5. Install heater core. Refer to Heater Core Replacement (See: Heater Core/Service and Repair). 6. Install air conditioning module wiring harness (1). Connect electrical connectors. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 6270 7. Install instrument panel tie bar (2). 1. Install 4 instrument panel tie bar bolts (3, 4) and tighten to 22 Nm (17 lb ft). 2. Install 2 instrument panel tie bar nuts (1) and tighten to 9 Nm (80 lb in). 8. Install instrument panel wiring harness (2) from instrument panel tie bar (1). Connect electrical connectors. 9. Install instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). 10. Fill the cooling system. Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). 11. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Procedures/Refrigerant Recovery and Recharging). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair Evaporator Core: Service and Repair Air Conditioning Evaporator Core Replacement Removal Procedure 1. Remove instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). 2. Remove instrument panel wiring harness (2) from instrument panel tie bar (1). Disconnect electrical connectors. 3. Remove instrument panel tie bar (2). 1. Remove 4 instrument panel tie bar bolts (3, 4). 2. Remove 2 instrument panel tie bar nuts (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Page 6274 4. Remove air conditioning module wiring harness (1). Disconnect electrical connectors. 5. Remove heater core. Refer to Heater Core Replacement (See: Heater Core/Service and Repair). 6. Remove blower motor. Refer to Blower Motor Replacement (Left Hand Drive) (See: Blower Motor/Service and Repair). 7. Remove heater and blower and air conditioning control module. Refer to Heater and Blower and Air Conditioning Control Module Replacement (Left Hand Drive) (See: Control Module HVAC/Service and Repair/HVAC - Automatic) or Heater and Blower and Air Conditioning Control Module Replacement (Left Hand Drive) (See: Control Module HVAC/Service and Repair/HVAC - Manual). 8. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Procedures/Refrigerant Recovery and Recharging). 9. Remove heater and air conditioning evaporator case (2) from heater and blower and air conditioning control module (1). 10. Remove 10 heater and air conditioning evaporator case bolts (3). 11. Remove air conditioning evaporator core from heater and blower and air conditioning control module. Installation Procedure 1. Install air conditioning evaporator core to heater and blower and air conditioning control module. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Page 6275 2. Install heater and air conditioning evaporator case (2) to heater and blower and air conditioning control module (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install 10 heater and air conditioning evaporator case bolts (3) and tighten to 2.5 Nm (22 lb in). 4. Refrigerant recovery and recharging. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Procedures/Refrigerant Recovery and Recharging). 5. Install heater and blower and air conditioning control module. Refer to Heater and Blower and Air Conditioning Control Module Replacement (Left Hand Drive) (See: Control Module HVAC/Service and Repair/HVAC - Automatic) or Heater and Blower and Air Conditioning Control Module Replacement (Left Hand Drive) (See: Control Module HVAC/Service and Repair/HVAC - Manual). 6. Install blower motor. Refer to Blower Motor Replacement (Left Hand Drive) (See: Blower Motor/Service and Repair). 7. Install heater core. Refer to Heater Core Replacement (See: Heater Core/Service and Repair). 8. Install air conditioning module wiring harness (1). Connect electrical connectors. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Page 6276 9. Install instrument panel tie bar (2). 1. Install 4 instrument panel tie bar bolts (3, 4) and tighten to 22 Nm (17 lb ft). 2. Install 2 instrument panel tie bar nuts (1) and tighten to 6 Nm (53 lb in). 10. Install instrument panel wiring harness (2) from instrument panel tie bar (1). Connect electrical connectors. 11. Install instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Service and Repair Evaporator Drain Tube: Service and Repair Air Conditioning Evaporator and Blower Module Drain Hose Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair Expansion Block/Orifice Tube: Service and Repair Air Conditioning Evaporator Thermal Expansion Valve Replacement Special Tools GE 39400-A - Halogen Leak Detector For equivalent regional tools, refer to Special Tools (See: Tools and Equipment/Heating, Ventilation, and Air Conditioning). Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Procedures/Refrigerant Recovery and Recharging). 2. Unclip brake pipes. 3. Remove the air conditioning evaporator hose bolt from the air conditioning evaporator thermal expansion valve. 4. Remove the air conditioning evaporator hose (1) from air conditioning evaporator thermal expansion valve. 5. Remove the 2 air conditioning evaporator thermal expansion valve bolts (2). 6. Remove the air conditioning evaporator thermal expansion valve (3). 7. Remove and DISCARD the seals from the air conditioning evaporator hose and from the evaporator core pipes. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > Page 6283 1. Install NEW system seals. Refer to Air Conditioning System Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install air conditioning evaporator thermal expansion valve (3) and the 2 air conditioning evaporator thermal expansion valve bolts (2) and tighten to 15 Nm (11 lb ft). 3. Install air conditioning evaporator hose (1) to air conditioning evaporator thermal expansion valve (3). Install and tighten hose bolt to 19 Nm (14 lb ft). 4. Install brake pipes. 5. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Procedures/Refrigerant Recovery and Recharging). 6. Leak test the fittings using the GE 39400-A - detector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair Heater Core: Service and Repair Heater Core Replacement Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). 2. Remove Instrument panel lower trim panel - left side. Refer to Instrument Panel Lower Trim Panel Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Trim Panel Replacement - Left Side). 3. Remove instrument outer trim cover - left side. Refer to Instrument Panel Outer Trim Cover Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Outer Trim Cover Replacement - Left Side). 4. Remove instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Pad Cover Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Trim Pad Cover Replacement). 5. Remove instrument panel bolt (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Page 6287 6. Remove heater core cover bolt (1) and heater core cover (2). 7. Remove the 2 heater core clamps (2). 8. Remove the 2 heater core tubes (3). 9. Remove the heater core (1). 10. Change the 2 heater core tube sealing rings. Installation Procedure 1. Install the heater core (1). 2. Install the 2 heater core tubes (3). 3. Tighten the 2 heater core clamps (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Page 6288 4. Install heater core cover bolt (1) and heater core cover (2). 5. Install instrument panel bolt (1). 6. Install instrument panel lower trim pad cover - left side. Refer to Instrument Panel Lower Trim Pad Cover Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Trim Pad Cover Replacement). 7. Install instrument outer trim cover - left side. Refer to Instrument Panel Outer Trim Cover Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Outer Trim Cover Replacement - Left Side). 8. Install instrument panel lower inner panel. Refer to Instrument Panel Lower Trim Panel Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Trim Panel Replacement - Left Side). 9. Bleed the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement Heater Hose: Service and Repair Heater Inlet Hose Replacement Heater Inlet Hose Replacement (1.4L LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 6293 Heater Hose: Service and Repair Heater Outlet Hose Replacement Heater Outlet Hose Replacement (1.4L LUJ) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). 2. Remove 2 heater outlet hose clamps (1). 3. Remove heater outlet hose (2). 4. Remove heater outlet hose clamps (2). 5. Remove heater outlet hose (3) from radiator surge tank (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 6294 1. Install heater outlet hose (3) to radiator surge tank (1). 2. Install heater outlet hose clamps (2). 3. Install heater outlet hose (2). 4. Install 2 heater outlet hose clamps (1). 5. Refill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE-47716 Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling (GE-47716 Fill)). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 6295 Heater Hose: Service and Repair Heater Core Outlet Tube Replacement Heater Core Outlet Tube Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 6296 Heater Hose: Service and Repair Heater Core Inlet Tube Replacement Heater Core Inlet Tube Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair High Pressure Safety Valve HVAC: Service and Repair Compressor Pressure Relief Valve Replacement (1.4L LUJ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Air Conditioning Compressor and Condenser Hose Replacement Hose/Line HVAC: Service and Repair Air Conditioning Compressor and Condenser Hose Replacement Air Conditioning Compressor and Condenser Hose Replacement (1.4L LUJ) Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Procedures/Refrigerant Recovery and Recharging). 2. Remove front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 3. Remove headlamp - right side. Refer to Headlamp Replacement (See: Lighting and Horns/Headlamp/Service and Repair). 4. Remove air conditioning compressor and condenser hose nut (1) from refrigerant hose (2). 5. Remove air conditioning compressor and condenser hose nut (3) from air conditioning condenser (4). 6. Remove and DISCARD the seals from the air conditioning compressor and condenser hose. 7. Remove air conditioning compressor and condenser hose bolt (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Air Conditioning Compressor and Condenser Hose Replacement > Page 6304 8. Remove air conditioning compressor and condenser hose. 9. Remove and DISCARD the air conditioning compressor and condenser hose seals (2). Installation Procedure 1. Install 4 NEW system seals to the air conditioning compressor and condenser hose. Refer to Air Conditioning System Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). 2. Install air conditioning compressor and condenser hose. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install air conditioning compressor and condenser hose bolt (1) tighten to 19 Nm (14 lb ft). 4. Install air conditioning compressor and condenser hose nut (3) to air conditioning condenser (4) and tighten to 19 Nm (14 lb ft). 5. Install air conditioning compressor and condenser hose nut (1) to air conditioning refrigerant hose (2) and tighten to 19 Nm (14 lb ft). 6. Install headlamp - right side. Refer to Headlamp Replacement (See: Lighting and Horns/Headlamp/Service and Repair). 7. Install front bumper fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 8. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Procedures/Refrigerant Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Air Conditioning Compressor and Condenser Hose Replacement > Page 6305 Recovery and Recharging). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Air Conditioning Compressor and Condenser Hose Replacement > Page 6306 Hose/Line HVAC: Service and Repair Air Conditioning Evaporator Hose Assembly Replacement Air Conditioning Evaporator Hose Assembly Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Air Conditioning Compressor and Condenser Hose Replacement > Page 6307 Hose/Line HVAC: Service and Repair Suction Screen Installation Suction Screen Installation Special Tools GE-44551 - Suction Screen Kit Installation Procedure Note: Suction screens are intended to be installed in the suction hose after a major compressor failure. 1. Remove the A/C compressor and condenser hose from the A/C compressor. Refer to Air Conditioning Compressor and Condenser Hose Replacement (1.4L LUJ) (See: Compressor HVAC/Service and Repair/Removal and Replacement/Air Conditioning Compressor and Condenser Hose Replacement)Air Conditioning Compressor and Condenser Hose Replacement (1.8L LUW) (See: Compressor HVAC/Service and Repair/Removal and Replacement/Air Conditioning Compressor and Condenser Hose Replacement). 2. Using a caliper that reads to 3 decimal places, measure the ID of the manifold suction fitting. To determine the correct size screen for the application, refer to Compressor Suction Screen and Tool Selection Specifications (See: Specifications/Mechanical Specifications/Heating, Ventilation, and Air Conditioning/Compressor Suction Screen and Tool Selection Specifications). 3. Select and install the correct mandrel (1) on the threaded portion of the installation tool bolt: * The brass universal mandrel is for use on hose fittings with a smooth bore where the screen installs flush with the end of the fitting. * The 11.96 mm (0.471 in) mandrel is only for the 11.96 mm (0.471 in) screen in hose fittings with an internal hourglass shape where the screen installs at the recessed, reduced diameter point. 4. Install the 11.96 mm (0.471 in) screen in the middle of the reduced diameter point of the fitting. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Air Conditioning Compressor and Condenser Hose Replacement > Page 6308 5. Place the suction hose side of the manifold into the GE-44551-5 - installation tool fixture (3) so it is supported by the tools legs. Note: Correct placement of the GE-44551-5 - installation tool fixture is critical. 6. Lubricate the A/C suction screen with the applicable refrigerant oil. 7. Align the screen (2), basket first into the suction hose bore then hand tighten the bolt until contact is made between the hose, screen and tool. 8. Turn the bolt of the installation tool clockwise pressing the screen into the bore until the mandrel shoulder contacts the end of the hose fitting. 9. Unscrew the bolt and remove the installation tool from the manifold. Note: Clean the surface to be used for attaching the label. 10. Install the GE-44551-1 - Suction Screen Notification Label. 11. Install the A/C compressor and condenser hose to the A/C compressor. Refer to Air Conditioning Compressor and Condenser Hose Replacement (1.4L LUJ) (See: Compressor HVAC/Service and Repair/Removal and Replacement/Air Conditioning Compressor and Condenser Hose Replacement)Air Conditioning Compressor and Condenser Hose Replacement (1.8L LUW) (See: Compressor HVAC/Service and Repair/Removal and Replacement/Air Conditioning Compressor and Condenser Hose Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Air Conditioning Compressor and Condenser Hose Replacement > Page 6309 Hose/Line HVAC: Service and Repair Suction Screen Replacement Suction Screen Replacement Special Tools GE-44551 - Suction Screen Kit Removal Procedure Note: Suction screens are intended to be installed in the suction hose after a major compressor failure. 1. Remove the A/C compressor and condenser hose from the A/C compressor. Refer to Air Conditioning Compressor and Condenser Hose Replacement (1.4L LUJ) (See: Compressor HVAC/Service and Repair/Removal and Replacement/Air Conditioning Compressor and Condenser Hose Replacement)Air Conditioning Compressor and Condenser Hose Replacement (1.8L LUW) (See: Compressor HVAC/Service and Repair/Removal and Replacement/Air Conditioning Compressor and Condenser Hose Replacement). 2. Using the GE-44551-9 - Universal Removal Tool , place the tip of the tool under the inside edge of the compression band of the suction screen and the cushioning fulcrum pad against the open end of the manifold fitting. Note: Do not damage the end of the hose or manifold. 3. Pry upward on the band and move the tool around the diameter of the screen as necessary to remove the screen. Installation Procedure 1. Using a caliper that reads to 3 decimal places, measure the ID of the manifold suction fitting. To determine the correct size screen for the application, refer to Compressor Suction Screen and Tool Selection Specifications (See: Specifications/Mechanical Specifications/Heating, Ventilation, and Air Conditioning/Compressor Suction Screen and Tool Selection Specifications). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Air Conditioning Compressor and Condenser Hose Replacement > Page 6310 2. Select and install the correct mandrel (1) on the threaded portion of the installation tool bolt: * The brass universal mandrel is for use on hose fittings with a smooth bore where the screen installs flush with the end of the fitting. * The 11.96 mm (0.471 in) mandrel is only for the 11.96 mm (0.471 in) screen in hose fittings with an internal hourglass shape where the screen installs at the recessed, reduced diameter point. * Install the 11.96 mm (0.471 in) screen in the middle of the reduced diameter point of the fitting. 3. Place the suction hose side of the manifold into the GE-44551-5 - installation tool fixture (3) so it is supported by the tools legs. Note: Correct placement of the GE-44551-5 - installation tool fixture is critical. 4. Lubricate the A/C suction screen with the applicable refrigerant oil. 5. Align the screen (2), basket first into the suction hose bore then hand tighten the bolt until contact is made between the hose, screen and tool. 6. Turn the bolt of the installation tool clockwise pressing the screen into the bore until the mandrel shoulder contacts the end of the hose fitting. 7. Unscrew the bolt and remove the installation tool from the manifold. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Air Conditioning Compressor and Condenser Hose Replacement > Page 6311 Note: Clean the surface to be used for attaching the label. 8. Install the GE-44551-1 - Suction Screen Notification Label. 9. Install the A/C compressor and condenser hose to the A/C compressor. Refer to Air Conditioning Compressor and Condenser Hose Replacement (1.4L LUJ) (See: Compressor HVAC/Service and Repair/Removal and Replacement/Air Conditioning Compressor and Condenser Hose Replacement)Air Conditioning Compressor and Condenser Hose Replacement (1.8L LUW) (See: Compressor HVAC/Service and Repair/Removal and Replacement/Air Conditioning Compressor and Condenser Hose Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair Receiver Dryer: Service and Repair Air Conditioning Refrigerant Desiccant Replacement Special Tools GE 39400-A - Halogen Leak Detector For equivalent regional tools, refer to Special Tools (See: Tools and Equipment/Heating, Ventilation, and Air Conditioning). Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Procedures/Refrigerant Recovery and Recharging). 3. Remove the air conditioning condenser. Refer to Air Conditioning Condenser Replacement (See: Condenser HVAC/Service and Repair). 4. Remove the air conditioning receiver and dehydrator plug (4). Note: Cap all air conditioning components immediately to prevent system contamination. 5. Remove and discard the sealing washers (3). 6. Remove the air conditioning refrigerant desiccant (2) from the air conditioning condenser (1). Installation Procedure 1. Uncap air conditioning components. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair > Page 6315 2. Install new sealing washers (3). 3. Install the air conditioning refrigerant desiccant (2) into air conditioning condenser (1). 4. Install the air conditioning receiver and dehydrator plug (4). 5. Install the air conditioning condenser (1). Refer to Air Conditioning Condenser Replacement (See: Condenser HVAC/Service and Repair). 6. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Procedures/Refrigerant Recovery and Recharging). 7. Leak test the fittings using the GE 39400-A - detector. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant System Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 6320 Refrigerant: Fluid Type Specifications Refrigerant System Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 6321 Refrigerant: Service and Repair Refrigerant Recovery and Recharging Special Tools GE-45037 - A/C Oil Injector For equivalent regional tools, refer to Special Tools (See: Tools and Equipment/Heating, Ventilation, and Air Conditioning). Refrigerant Recovery and Recharging Warning To prevent personal injury, avoid breathing A/C Refrigerant and lubricant vapor or mist. Work in a well ventilated area. To remove refrigerant from the A/C System, use service equipment designed for recovery that is certified to meet the requirements of the appropriate SAE Standards. If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant, refrigerant recovery, and lubricant manufacturers. Warning For personal protection, goggles and lint-free gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If refrigerant comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Caution: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. Caution: To avoid system damage use only R-134a dedicated tools when servicing the A/C system. Caution: Do not mix refrigerant oils. Use of incorrect refrigerant oil will cause compressor failure. Caution: R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The AC filling device is a complete air conditioning service center for R-134a. The AC filling device recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The AC filling device automatically replenishes this vessel from an external source tank in order to maintain a constant volume of A/C refrigerant. The AC filling device has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the AC filling device will not recover the refrigerant from the A/C system. The AC filling device also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the AC filling device manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Specifications (See: Specifications/Capacity Specifications). A/C Refrigerant System Oil Charge Replenishing If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using GE-45037 - injector. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Specifications (See: Specifications/Capacity Specifications). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications Refrigerant Oil: Specifications Refrigerant System Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Powertrain Component Views Lower Right Side of the Engine Components 1 - B1 A/C Refrigerant Pressure Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6328 Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Temperature Sensor > Component Information > Service and Repair > HVAC - Automatic Refrigerant Temperature Sensor: Service and Repair HVAC - Automatic Air Conditioning Refrigerant Temperature Sensor Replacement - Right Side (Left Hand Drive) Air Conditioning Refrigerant Temperature Sensor Replacement - Right Side (Left Hand Drive) Air Conditioning Refrigerant Temperature Sensor Replacement - Left Side (Left Hand Drive) Air Conditioning Refrigerant Temperature Sensor Replacement - Left Side (Left Hand Drive) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Temperature Sensor > Component Information > Service and Repair > HVAC - Automatic > Page 6333 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Temperature Sensor > Component Information > Service and Repair > HVAC - Automatic > Page 6334 Refrigerant Temperature Sensor: Service and Repair HVAC - Manual Air Conditioning Refrigerant Temperature Sensor Replacement - Right Side (Left Hand Drive) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6339 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6340 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6341 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations Control Module HVAC: Locations Instrument Panel/Center Console Component Views Behind the Center of the I/P Components (C68) 1 - X212 Instrument Panel Harness and HVAC Haness 2 - X3 HVAC Control Module X3 3 - K33 HVAC Control Module 4 - X2 Blower Motor Control Module X2 5 - K8 Blower Motor Control Module 6 - M8 Blower Motor 7 - X1 Blower Motor Control Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 6345 Control Module HVAC: Diagrams Component Connector End Views K8 Blower Motor Control Module X1 K8 Blower Motor Control Module X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 6346 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic Control Module HVAC: Service and Repair HVAC - Automatic Heater and Blower and Air Conditioning Control Module Replacement (Left Hand Drive) Removal Procedure 1. Remove instrument panel compartment. Refer to Instrument Panel Compartment Replacement (See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Compartment Replacement). 2. Remove floor air outlet duct right side. Refer to Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive) (See: Air Duct/Service and Repair/Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive)). 3. Remove the 2 heater and blower and air conditioning control module bolts (1) and the heater and blower and air conditioning control module wiring harness plug (2). 4. Remove heater and blower and air conditioning control module (3). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6349 1. Install heater and blower and air conditioning control module (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the heater and blower and air conditioning control module wiring harness plug (2) and the 2 heater and blower and air conditioning control module bolts (1). Tighten to 2.5 Nm (23 lb in). 3. Install floor air outlet duct - right side. Refer to Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive) (See: Air Duct/Service and Repair/Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive)). 4. Install instrument panel compartment. Refer to Instrument Panel Compartment Replacement (See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Compartment Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6350 Control Module HVAC: Service and Repair HVAC - Manual Heater and Blower and Air Conditioning Control Module Replacement (Left Hand Drive) Removal Procedure 1. Remove instrument panel compartment. Refer to Instrument Panel Compartment Replacement (See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Compartment Replacement). 2. Remove floor air outlet duct right side. Refer to Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive) (See: Air Duct/Service and Repair/Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive)). 3. Remove the 2 heater and blower and air conditioning control module bolts (1) and the heater and blower and air conditioning control module wiring harness plug (2). 4. Remove heater and blower control module (3). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 6351 1. Install heater and blower control module (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the heater and blower and air conditioning control module wiring harness plug (2) and the 2 heater and blower and air conditioning control module bolts (1). Tighten to 2.5 Nm (22 lb in). 3. Install floor air outlet duct right side. Refer to Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive) (See: Air Duct/Service and Repair/Floor Air Outlet Duct Replacement - Right Side (Left Hand Drive)). 4. Install instrument panel compartment. Refer to Instrument Panel Compartment Replacement (See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Compartment Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Locations Air Conditioning Switch: Locations Component Connector End Views S34 HVAC Controls Switch Assembly Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications Ambient Temperature Sensor / Switch HVAC: Specifications Ambient Air Temperature Sensor Resistance Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views Ambient Temperature Sensor / Switch HVAC: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components 2 of 2 1 - B108 Air Quality Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Front of Vehicle/Engine Compartment Component Views > Page 6361 Ambient Temperature Sensor / Switch HVAC: Locations Wheels/Vehicle Underbody Component Views Wheels/Vehicle Underbody Component Views Left Front Frame and Underbody Components 2 of 2 1 - B9 Air Temperature Sensor - Ambient Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6362 Ambient Temperature Sensor / Switch HVAC: Diagrams Component Connector End Views B9 Air Temperature Sensor - Ambient Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6363 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Quality Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations Cabin Temperature Sensor / Switch: Locations Instrument Panel/Center Console Component Views Behind the Left Side of the I/P Components (C68) 1 - 7D Air Temperature Sensor - Duct Left Lower 2 - M6L Air Temperature Door Actuator - Left 3 M37 Mode Door Actuator 4 - B7H Air Temperature Sensor - Duct Left Upper Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Inside Air Temperature Sensor Replacement (Left Hand Drive) Cabin Temperature Sensor / Switch: Service and Repair Inside Air Temperature Sensor Replacement (Left Hand Drive) Inside Air Temperature Sensor Replacement (Left Hand Drive) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Inside Air Temperature Sensor Replacement (Left Hand Drive) > Page 6369 Cabin Temperature Sensor / Switch: Service and Repair Inside Air Moisture and Windshield Temperature Sensor Replacement Inside Air Moisture and Windshield Temperature Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Climate Control Exhaust Gas Sensor > Component Information > Diagrams Climate Control Exhaust Gas Sensor: Diagrams Component Connector End Views B108 Air Quality Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Powertrain Component Views Lower Right Side of the Engine Components 1 - B1 A/C Refrigerant Pressure Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6376 Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Temperature Sensor > Component Information > Service and Repair > HVAC - Automatic Refrigerant Temperature Sensor: Service and Repair HVAC - Automatic Air Conditioning Refrigerant Temperature Sensor Replacement - Right Side (Left Hand Drive) Air Conditioning Refrigerant Temperature Sensor Replacement - Right Side (Left Hand Drive) Air Conditioning Refrigerant Temperature Sensor Replacement - Left Side (Left Hand Drive) Air Conditioning Refrigerant Temperature Sensor Replacement - Left Side (Left Hand Drive) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Temperature Sensor > Component Information > Service and Repair > HVAC - Automatic > Page 6381 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Temperature Sensor > Component Information > Service and Repair > HVAC - Automatic > Page 6382 Refrigerant Temperature Sensor: Service and Repair HVAC - Manual Air Conditioning Refrigerant Temperature Sensor Replacement - Right Side (Left Hand Drive) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Service and Repair Solar Sensor: Service and Repair Sun Load Temperature and Headlamp Automatic Control Ambient Light Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ventilation Switch > Component Information > Service and Repair Ventilation Switch: Service and Repair Vent Valve Lever Replacement (Left Hand Drive) Removal Procedure 1. Remove instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Note: The graphic shows air inlet housing without attaching parts for better clarity. 2. Disconnect electrical connector and remove 3 mode control cam actuator screws (2) and remove mode control cam actuator (1). 3. Remove air inlet valve and inside air valve control cam (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ventilation Switch > Component Information > Service and Repair > Page 6389 4. Remove 2 vent valve levers (1). Installation Procedure 1. Install 2 vent valve levers (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ventilation Switch > Component Information > Service and Repair > Page 6390 Note: The vent valve levers have to be fitted to the according vent valve gears in figured position. The air circulation dampers have to be in middle position. 2. Make sure that mode valve gears of valve vent levers (1) are fitted as shown in graphic above Note: The air inlet valve and inside air valve control cam can only be fitted in one position. 3. Install air inlet valve and inside air valve control cam (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ventilation Switch > Component Information > Service and Repair > Page 6391 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install mode control cam actuator (1) and install 3 mode control cam actuator screws (2) and connect electrical connector. 2.5 Nm (23 lb in). 5. Install instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Service and Repair Service Port HVAC: Service and Repair Air Conditioning Refrigerant Service Valve Core Replacement Special Tools * GE-39400-A - Halogen Leak Detector * GE-46246 - Valve Core Removal Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment/Heating, Ventilation, and Air Conditioning). Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Procedures/Refrigerant Recovery and Recharging). 2. Remove the service port valve core (1) using GE-46246 - remover. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Service and Repair > Page 6395 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the service port valve core using (1) GE-46246 - remover and tighten to 3 Nm (22 lb in). 2. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Procedures/Refrigerant Recovery and Recharging). 3. Leak test the fittings using the GE-39400-A - detector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Service and Repair Solar Sensor: Service and Repair Sun Load Temperature and Headlamp Automatic Control Ambient Light Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ventilation Switch > Component Information > Service and Repair Ventilation Switch: Service and Repair Vent Valve Lever Replacement (Left Hand Drive) Removal Procedure 1. Remove instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Note: The graphic shows air inlet housing without attaching parts for better clarity. 2. Disconnect electrical connector and remove 3 mode control cam actuator screws (2) and remove mode control cam actuator (1). 3. Remove air inlet valve and inside air valve control cam (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ventilation Switch > Component Information > Service and Repair > Page 6402 4. Remove 2 vent valve levers (1). Installation Procedure 1. Install 2 vent valve levers (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ventilation Switch > Component Information > Service and Repair > Page 6403 Note: The vent valve levers have to be fitted to the according vent valve gears in figured position. The air circulation dampers have to be in middle position. 2. Make sure that mode valve gears of valve vent levers (1) are fitted as shown in graphic above Note: The air inlet valve and inside air valve control cam can only be fitted in one position. 3. Install air inlet valve and inside air valve control cam (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ventilation Switch > Component Information > Service and Repair > Page 6404 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install mode control cam actuator (1) and install 3 mode control cam actuator screws (2) and connect electrical connector. 2.5 Nm (23 lb in). 5. Install instrument panel assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Seat Belts Repairs and Inspections Required After a Collision: Service and Repair Seat Belts Repairs and Inspections Required After a Collision Warning Restraint systems can be damaged in a collision. To help avoid injury and ensure that all parts in need of replacement are replaced: * Replace any seat belt system that was in use during the collision serious enough to deploy any automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat belt systems in use by people of adult size, but seat belt systems used to secure child restraints, infant carriers and booster seats, including LATCH system and top tether anchorages. * Replace any seat belt system that has torn, worn, or damaged components. This not only includes adult seat belt systems, but built-in child restraints and LATCH system components, if any. * Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow tag is visible. Do not replace a seat belt if only the child seat caution label is visible. * Replace any seat belt system if you are doubtful about its condition. This not only includes adult seat belt systems, but built-in child restraints, LATCH system components, and any restraint system used to secure infant carriers, child restraints, and booster seats. Do NOT replace single seat belt system components in vehicles that have been in a collision as described above. Always replace the entire seat belt system with the buckle, guide and retractor assembly, which includes the latch and webbing material. After a minor collision where no automatic restraint device was deployed, seat belt system replacement may not be necessary, unless some of the parts are torn, worn, or damaged. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Seat Belts > Page 6410 Repairs and Inspections Required After a Collision: Service and Repair Supplemental Inflatable Restraints Repairs and Inspections Required After a Collision Accident With or Without Air Bag Deployment - Component Inspections Warning Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than intended. After any collision, inspect the following components as indicated. If you detect any damage, replace the component. If you detect any damage to the mounting points or mounting hardware, repair the component or replace the hardware as needed. * The steering column-Inspect the steering column for bending, twisting, buckling or any type of damage. * The instrument panel knee bolsters and mounting points-Inspect the knee bolsters for bending, twisting, buckling, or any other type of damage. * The instrument panel brackets, braces, etc.-Inspect for bending, twisting, buckling, or any other type of damage. * The seat belts-Perform the seat belt operational and functional checks. Refer to Repairs and Inspections Required After a Collision (See: Seat Belts). * The instrument panel cross car beam-Inspect for bending, twisting, buckling, or any other type of damage. * The instrument panel mounting points and brackets-Inspect for bending, twisting, buckling, or any other type of damage. * The seats and seat mounting points-Inspect for bending, twisting, buckling, or any other type of damage. * The roof and headliner mounting points. Accident With Frontal Air Bag Deployment - Component Replacement and Inspections After a collision involving air bag deployment, replace the following components. * Passenger instrument panel air bag * Driver steering wheel air bag * Inflatable restraint sensing and diagnostic module (SDM) * Front and/or side impact sensors * Driver/Passenger seat side air bag, if deployed * Seat back cover on if side seat air bag is deployed * Driver/Passenger seat belt anchor and/or retractor pretensioners Perform additional inspections on the following components. * Steering wheel air bag coil and the coil wiring pigtail-Inspect for melting, scorching, or other damage due to excessive heat. * Mounting points or mounting hardware for the passenger instrument panel air bag, steering wheel air bag, SDM, seat side air bag (if deployed) and seat belt anchor and/or retractor pretensioners-Inspect for any damage and repair or replace each component as needed. Accident With Side Seat Air Bag Deployment - Component Replacement and Inspections After a collision involving driver/passenger side seat air bag deployment, replace the following components. * Left/right side impact sensors on the side of the impact. * Left/right roof rail air bag on the side of the impact. * Inflatable restraint sensing and diagnostic module (SDM), if SDM has DTC B0052 56. * Inflatable restraint seat belt anchor and/or retractor pretensioner. * Driver or passenger seat back cushion cover replacement. Warning Do not repair or replace the seat stitching or seams in the seat back trim cover with an internal mounted seat side airbag module. Replace the complete seat back trim cover from the OEM. Non-OEM seat stitching may cause improper airbag deployment which could result in personal injury. Perform additional inspections on the following components. * Mounting points or mounting hardware for the side impact sensors, and driver/passenger side seat air bags on the side of impact-Inspect for any damage and repair or replace each component as needed. * Mounting points, mounting hardware, headliner and trim pieces for the left/right roof rail air bag on the side of impact-Inspect for any damage and repair or replace each component as needed. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Seat Belts > Page 6411 * Mounting points or mounting hardware for the SDM and seat belt anchor and/or retractor pretensioners-Inspect for any damage and repair or replace each component as needed. * The seat cushion frame * The seat recliner and cover, if equipped * The seat adjuster * The seat back frame * Door trim assembly * Impacted seat cushion side covers and switches Impact Sensor Replacement Guidelines The impact sensor replacement policy requires replacing sensors in the area of the accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. An example of this would be a moderate collision where the front of the vehicle impacts a object. If the vehicle has an impact sensor mounted forward of the radiator, it must be replaced. * Replace the impact sensor whether or not the air bags have deployed. * Replace the impact sensor even if it appears to be undamaged. Impact sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR system. Do not try to determine whether the impact sensor is undamaged, replace the impact sensor. Also, if you follow a diagnostic trouble code (DTC) procedure and a malfunctioning impact sensor is indicated, replace the impact sensor. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 6416 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams Air Bag: Diagrams Component Connector End Views F105 Passenger Instrument Panel Air Bag F105L Roof Rail Air Bag - Left Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Page 6420 F105R Roof Rail Air Bag - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Procedures Air Bag: Procedures Inflatable Restraint Module Handling and Scrapping Special Tools * EL-38826 - SIR Deployment Harness * EL-39401-B - SIR Deployment Fixture For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Live and Undeployed Air Bag Warning: Refer to SIR Inflator Module Handling and Storage Warning (See: Service Precautions/SIR Inflator Module Handling and Storage Warning). Take special care when handling or storing an undeployed air bag. An air bag deployment produces a rapid generation of gas. This may cause the air bag, or an object in front of the air bag, to project through the air in the event of an unlikely deployment. Dual Stage Air Bags Dual stage air bags have two deployment stages. If stage 1 was used to deploy a dual stage air bag, stage 2 may still be active. Therefore, a deployed dual stage air bag must be treated as an active air bag. If disposal of a dual stage air bag is required, both deployment loops must be energized to deploy the air bag. Scrapping Procedure During the course of a vehicle's useful life, certain situations may arise which will require the disposal of a live and undeployed air bag. Do NOT dispose a live and undeployed air bag through normal disposal channels until the air bag has been deployed. Do not deploy the air bag in the following situations: * After replacement of an air bag under warranty-the air bag may need to be returned undeployed to the manufacturer. * If the vehicle is the subject of a product liability claim, related to the SIR system and is subject to a preliminary investigation - do NOT alter the SIR system in any manner. * If the vehicle is involved in a campaign affecting the air bags - follow the instructions in the campaign service bulletin for proper SIR handling procedures. Deployment Procedures You can deploy the air bag either inside or outside of the vehicle. The method used depends upon the final disposition of the vehicle. Review the following procedures in order to determine which will work best in a given situation: Deployment Outside Vehicle - Steering Wheel Air Bag, Instrument Panel Air Bag, and Roof Rail Air Bag Deploy the air bag outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: * Using the SIR diagnostics, you determine that the air bag is malfunctioning. * The air bag is cosmetically damaged, scratched, or ripped. * The air bag pigtail is damaged. * The air bag connector is damaged. * The air bag connector terminals are damaged. Deployment and disposal of a malfunctioning air bag is subject to any required retention period. Warning: Refer to SIR Inflator Module Disposal Warning (See: Service Precautions/SIR Inflator Module Disposal Warning). 1. Turn OFF the ignition. Warning: Refer to SIR Inflator Module Handling and Storage Warning (See: Service Precautions/SIR Inflator Module Handling and Storage Warning). 2. Remove the air bag. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Procedures > Page 6423 3. Clear a space on the ground about 1.85 m (6 ft) in diameter for deployment of the air bag or deployment fixture. If possible, use a paved, outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Ensure you have sufficient ventilation. 4. Clear the area of loose or flammable objects. Note: Dual stage deployments are only used in steering wheel and instrument panel air bags. If stage 1 was used to deploy a dual stage air bag, stage 2 may still be active. If disposal of a dual stage air bag is required, both deployment loops must be energized to deploy the air bag. 5. If you are deploying a steering wheel air bag, place the air bag in the center of the space with the vinyl trim cover facing up and away from the surface. 6. When deploying an instrument panel air bag, perform the following instructions: 1. Place the EL-39401-B - fixture in the center of the cleared area. 2. Fill the deployment fixture with water or sand. 3. Using the proper nuts and bolts, mount the instrument panel air bag (1) to the deployment fixture (2), with the vinyl trim facing up. 4. Securely tighten all fasteners that hold the instrument panel air bag (1) to the deployment fixture (2). 7. When deploying a roof rail air bag, perform the following instructions: 1. Place the EL-39401-B - fixture (3) in the center of the cleared area. 2. Fill the deployment fixture with water or sand to provide sufficient stabilization of fixture during deployment. 3. Adjust and secure the fixture arms (4) to the deployment fixture (3), using the proper nuts and bolts. 4. Attach the roof rail air bag in the deployment fixture and securely tighten all fasteners. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Procedures > Page 6424 8. Inspect the EL-38826 - harness and the appropriate pigtail adapter (2) for damage. Replace as needed. 9. Short the 2 SIR deployment harness leads (1) together using one banana plug seated into the other. 10. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). 11. Extend the SIR deployment harness and adapter to the full length from the deployment fixture or area. Note: On a dual stage air bag, both connectors must be attached to the deployment harness adapter. This will ensure that both stage 1 and stage 2 of the deployment loops are energized, regardless of the deployment state. 12. Connect the air bag (1) to the adapter (2) on the SIR deployment harness (3). Note: * The rapid expansion of gas involved with deploying an air bag is very loud. Notify all the people in the immediate area that you intend to deploy the air bag. * When the air bag deploys, the deployment fixture may jump about 30 cm (1 ft) vertically. This is a normal reaction of the air bag due to the force of the rapid expansion of gas inside the air bag. * If you are deploying a dual stage air bag with stage 1 already deployed, the fixture may not move and the noise may have been reduced. 13. Clear the area of people. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Procedures > Page 6425 14. Separate the 2 banana plugs on the SIR deployment harness that were shorted together earlier in the procedure. 15. Place a 12 V minimum/2A minimum power source, such as a vehicle battery, near the shorted end of the harness. 16. Connect the SIR deployment harness wires to the power source. Deployment of the air bag will occur when contact is made. 17. Disconnect the SIR deployment harness from the power source after the air bag deploys. 18. If the air bag did not deploy, disconnect the adapter and discontinue the procedure and contact the Technical Assistance Group. If deployment was successful, proceed to the following steps. Warning: Refer to SIR Deployed Inflator Modules Are Hot Warning (See: Service Precautions/SIR Deployed Inflator Modules Are Hot Warning). 19. Seat one banana plug into the other in order to short the deployment harness leads. 20. Put on a pair of shop gloves. 21. Disconnect the pigtail adapter from the air bag as soon as possible. 22. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed. 23. Dispose of the deployed air bag through normal refuse channels. 24. Wash your hands with a mild soap. Deployment Inside Vehicle - Vehicle Scrapping Procedure Deploy the air bags inside of the vehicle when destroying the vehicle or when salvaging the vehicle for parts. This includes, but is not limited to, the following situations: * The vehicle has completed all useful life. * Irreparable damage occurred to the vehicle in a non-deployment type accident. * Irreparable damage occurred to the vehicle during a theft. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Procedures > Page 6426 * The vehicle is being salvaged for parts to be used on a vehicle with a different VIN, as opposed to rebuilding as the same VIN. Warning: Refer to SIR Inflatable Module Deployment Outside Vehicle Warning (See: Service Precautions/SIR Inflatable Module Deployment Outside Vehicle Warning). 1. Lower the driver and passenger windows. 2. Turn the ignition switch to the OFF position and remove the ignition key. 3. Check that all air bags which will be deployed are mounted securely. 4. Remove all loose objects from the front seats. Warning A deployed dual stage inflator module will look the same whether one or both stages were used. Always assume a deployed dual stage inflator module has an active stage 2. Improper handling or servicing can activate the inflator module and cause personal injury. 5. Disconnect the steering wheel air bag yellow connector (1) from vehicle harness yellow connector (3). Note: If the vehicle is equipped with dual stage air bags the steering wheel air bag and instrument panel air bag will each have 4 wires. Refer to Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) for determining high and low circuits. 6. Cut the yellow harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 7. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Procedures > Page 6427 8. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gauge) or thicker multi-strand wire. Use these wires to fabricate the driver deployment harness. 9. Strip 13 mm (0.5 in) of insulation from both ends of the wires. 10. Twist together one end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the air bag. 11. Twist together the 2 connector wire leads from the high circuits from both stages of the steering wheel air bag, to one set of deployment wires. Refer to Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) in order to determine the correct circuits. 12. Inspect that the 3-wire connection is secure. 13. Secure and insulate the 3-wire connection to the deployment harness using electrical tape. 14. Twist together the 2 connector wire leads from the low circuits from both stages of the steering wheel air bag, to one set of deployment wires. Refer to Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) in order to determine the correct circuits. 15. Inspect that the 3-wire connection is secure. 16. Secure and insulate the 3-wire connection to the deployment harness using electrical tape. 17. Connect the deployment harness to the connector on the steering wheel air bag. 18. Route the deployment harness out of the driver side of the vehicle. 19. Disconnect the yellow left roof rail harness connector from the vehicle harness connector. 20. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 21. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 22. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gauge) or thicker multi-strand wire. These wires will be used to fabricate the roof rail air bag deployment harness. 23. Strip 13 mm (0.5 in) of insulation from both ends of the wires. 24. Twist together one end from each of the wires in order to short the wires. 25. Twist together one connector wire lead to one deployment wire. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Procedures > Page 6428 26. Secure and insulate the connection using electrical tape. 27. Twist together and tape the remaining connector wire lead to the remaining deployment wire. 28. Connect the deployment harness to the yellow connector of the roof rail air bag. 29. Route the deployment harness out of the driver side of the vehicle. 30. Disconnect the instrument panel air bag yellow harness connector (1) from the vehicle harness connector (2). Note: If the vehicle is equipped with dual stage air bags the steering wheel air bag and instrument panel air bag will each have 4 wires. Refer to Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) for determining high and low circuits. 31. Cut the yellow harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 32. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 33. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gauge) or thicker multi-strand wire. These wires will be used to fabricate the passenger deployment harness. 34. Strip 13 mm (0.5 in) of insulation from both ends of the wires. 35. Twist together one end from each of the wires in order to short the wires. 36. Twist together the 2 connector wire leads from the high circuits from both stages of the instrument panel air bag to one set of deployment wires. Refer to Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) in order to determine the correct circuits. 37. Inspect that the 3-wire connection is secure. 38. Secure and insulate the 3-wire connection to the deployment harness using electrical tape. 39. Twist together the 2 connector wire leads from the low circuits from both stages of the instrument panel air bag to one set of deployment wires. Refer to Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) in order to determine the correct circuits. 40. Inspect that the 3-wire connection is secure. 41. Secure and insulate the 3-wire connection to the deployment harness using electrical tape. 42. Connect the deployment harness to the instrument panel air bag in-line connector. 43. Route the deployment harness out of the passenger side of the vehicle. 44. Disconnect the yellow harness connector to the right roof rail air bag from the vehicle harness connector. 45. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 46. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 47. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gauge) or thicker multi-strand wire. These wires will be used to fabricate the roof rail air bag deployment harness. 48. Strip 13 mm (0.5 in) of insulation from both ends of the wires. 49. Twist together one end from each of the wires in order to short the wires. 50. Twist together one connector wire lead to one deployment wire. 51. Secure and insulate the connection using electrical tape. 52. Twist together and tape the remaining connector wire lead to the remaining deployment wire. 53. Connect the deployment harness to the roof rail air bag yellow connector. 54. Route the deployment harness out of the passenger side of the vehicle. 55. Completely cover the windshield and the front door window openings with a drop cloth. 56. Stretch to the full length all of the deployment harness wires on the right side of the vehicle. 57. Deploy each deployment loop one at a time. 58. Place a power source, 12 V minimum/2A minimum, such as a vehicle battery, near the shorted end of the harnesses. 59. Separate one set of wires and touch the wire ends to the power source in order to deploy the selected air bag. 60. Disconnect the deployment harness from the power source and twist the wire ends together. 61. Continue the same process with the remaining deployment harnesses. 62. Disconnect all harnesses from the vehicle. 63. Discard the harnesses. 64. Scrap the vehicle in the same manner as a non-SIR equipped vehicle. 65. If one or all of the air bags did not deploy, remove the undeployed air bags from the vehicle. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Procedures > Page 6429 Air Bag: Removal and Replacement Driver or Passenger Seat Side Inflatable Restraint Module Replacement Driver or Passenger Seat Side Inflatable Restraint Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Procedures > Page 6430 Inflatable Restraint Instrument Panel Lower Module Replacement - Driver Side Inflatable Restraint Instrument Panel Lower Module Replacement - Driver Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Procedures > Page 6431 Inflatable Restraint Instrument Panel Lower Module Replacement - Passenger Side Inflatable Restraint Instrument Panel Lower Module Replacement - Passenger Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Procedures > Page 6432 Rear Seat Side Inflatable Restraint Module Replacement Rear Seat Side Inflatable Restraint Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Procedures > Page 6433 Roof Side Rail Inflatable Restraint Module Replacement Roof Side Rail Inflatable Restraint Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Procedures > Page 6434 Steering Wheel Inflatable Restraint Module Replacement Steering Wheel Inflatable Restraint Module Replacement Removal Procedure Warning When carrying a live inflator module, make sure the bag opening is pointed away from you. This minimizes the chance of injury in the case of an accidental deployment. Never carry the inflator module by the wires. Never carry the inflator module by the connector on the underside of the module. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Procedures > Page 6435 Make sure that the bag and trim cover are facing up whenever you place a live inflator module on any surface. This is necessary to provide a free space for the bag to expand in the unlikely event of accidental deployment. Never rest the steering column assembly on the steering wheel with the inflator module face down, and the column vertical. This may result in personal injury. Warning: Refer to SIR Warning (See: Service Precautions/SIR Warning). 1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). 2. Insert suitable tools to the openings (2) on both sides of the steering wheel (1). 3. Release the springs in direction of the arrows. 4. Disconnect the electrical connectors. Installation Procedure 1. Connect the electrical connectors (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Procedures > Page 6436 2. Align the steering wheel module fasteners to the steering column fastener holes. 3. Push the steering wheel module (1) firmly into the steering column in order the engage the fasteners. 4. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). 5. After replacing the module, fully deploy the old module before disposal. Instrument Panel Inflatable Restraint Module Replacement Instrument Panel Inflatable Restraint Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Procedures > Page 6437 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Instrument Panel/Center Console Component Views Behind the Center of the I/P Components 3 of 4 1 - K36 Inflatable Restraint Sensing and Diagnostic Module 2 - X2 Inflatable Restraint Sensing and Diagnostic Module X2 3 - X1 Inflatable Restraint Sensing and Diagnostic Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6441 Air Bag Control Module: Diagrams Component Connector End Views K36 Inflatable Restraint Sensing and Diagnostic Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6442 Air Bag Control Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information > Diagrams Air Bag Deactivation Indicator: Diagrams Component Connector End Views P14 Passenger Air Bag Disable Indicator Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information > Diagrams > Page 6446 Air Bag Deactivation Indicator: Service and Repair Inflatable Restraint Instrument Panel Module Indicator Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Clockspring Assembly / Spiral Cable: Diagrams Component Connector End Views X85 Steering Wheel Air Bag Coil X1 X85 Steering Wheel Air Bag Coil X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 6450 X85 Steering Wheel Air Bag Coil X3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 6451 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures Clockspring Assembly / Spiral Cable: Procedures Inflatable Restraint Steering Wheel Module Coil Centering Caution: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. 1. Verify the following conditions before centering the supplemental inflatable restraint (SIR) steering wheel module coil: * The wheels on the vehicle are straight ahead. * The centering mark (1) of the steering shaft is in the 6 o'clock position. 2. Turn the lobe of the clock spring clockwise until the coil ribbon stops. Do not force. 3. Turn the lobe of the clock spring counterclockwise approximately 3 turns to the Neutral position. 4. Properly align until the centering window turns yellow (1). This indicates the CENTER position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures > Page 6454 Clockspring Assembly / Spiral Cable: Removal and Replacement Steering Wheel Inflatable Restraint Module Coil Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations Passenger Compartment/Roof Component Views Left Rear of the Passenger Compartment Components 1 of 2 1 - F105L Roof Rail Air Bag - Left 2 - B63LR Side Impact Sensor - Left Rear 3 - B5LR Wheel Speed Sensor - Left Rear 4 - G309 Panel Rear - Left 5 - G401 Panel Rear - Left Left Side of the Passenger Compartment Components Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6458 1 - B63LF Side Impact Sensor - Left Front 2 - F112D Seat Belt Retractor Pretensioner - Driver Right Rear of the Passenger Compartment Components 1 of 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6459 1 - T3 Audio Amplifier 2 - P19AA Speaker - Right Subwoofer 3 - X1 Audio Amplifier X1 4 - X2 Audio Amplifier X2 5 - X3 Audio Amplifier X3 6 - B63RR Side Impact Sensor - Right Rear Right Side of the Passenger Compartment Components 3 of 3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6460 1 - F112P Seat Belt Retractor Pretensioner - Passenger 2 - B63RF Side Impact Sensor - Right Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6461 Impact Sensor: Diagrams Component Connector End Views B59L Front Impact Sensor - Left B59R Front Impact Sensor - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6462 B63LF Side Impact Sensor - Left Front B63LR Side Impact Sensor - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6463 B63RF Side Impact Sensor - Right Front B63RR Side Impact Sensor - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6464 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Side Impact Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement Inflatable Restraint Side Impact Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Side Impact Sensor Replacement > Page 6467 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Side Impact Sensor Replacement > Page 6468 Impact Sensor: Service and Repair Front End Inflatable Restraint Discriminating Sensor Replacement Front End Inflatable Restraint Discriminating Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Service and Repair > Inflatable Restraint Front Passenger Presence Sensor Replacement Seat Occupant Sensor: Service and Repair Inflatable Restraint Front Passenger Presence Sensor Replacement Inflatable Restraint Front Passenger Presence Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Service and Repair > Inflatable Restraint Front Passenger Presence Sensor Replacement > Page 6475 Seat Occupant Sensor: Service and Repair Inflatable Restraint Front Passenger Presence Module Replacement Inflatable Restraint Front Passenger Presence Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Instrument Panel/Center Console Component Views Behind the Center of the I/P Components 3 of 4 1 - K36 Inflatable Restraint Sensing and Diagnostic Module 2 - X2 Inflatable Restraint Sensing and Diagnostic Module X2 3 - X1 Inflatable Restraint Sensing and Diagnostic Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6484 Air Bag Control Module: Diagrams Component Connector End Views K36 Inflatable Restraint Sensing and Diagnostic Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6485 Air Bag Control Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Air Bag Systems/Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 6490 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Air Bag Systems/Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions Seat Belt: Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions INFORMATION Bulletin No.: 05-09-40-002E Date: October 21, 2010 Subject: Safety Belt Locking Conditions (Normal Operating Characteristic) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 05-09-40-002D (Section 09 - Restraints). The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are several different locking situations for both front and rear safety belts. Overspool Lock There is an unintentional locking condition that ALL safety belts from ALL manufacturers may experience called "overspool lock". If the webbing snaps back to the stowed position rapidly enough, the retractor will lock with the belt fully stowed. This is more likely to occur when customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the retractive speed of the webbing, the higher than normal webbing retraction speed that occurs engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT replace the retractor for this condition until first attempting to disengage the locking mechanism by following the recommendation listed below. Recommendation Pull hard on the locked webbing and then release. The hard pull extracts a small amount of webbing from the retractor which, in turn, permits a small amount of retraction to occur when released. This is all that is needed to disengage the locking mechanism. The safety belt will now function properly. Vehicle Sensing This type of locking occurs in response to the vehicle under the following conditions: - The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR rapid deceleration or there is aggressive cornering). - It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or side-to-side), such as streets in San Francisco, California. - It may also occur over rough road conditions where the retractor mechanism is bounced into a locked condition. In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked. When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt should return to normal function. Please inform customers that may comment that "the belt locks intermittently" that this is the design intent and the belt is functioning properly. Web Sensing This type of locking occurs in response to the extraction of webbing. When the webbing reels out at an accelerated rate, it goes into lock mode and stays there until tension is again released. To observe this condition, extract the webbing quickly. Customers may refer to this condition as "intermittent lock-up" and encounter it when trying to put the belt on too quickly. Automatic Locking (ALR) When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to the end of travel while they are putting the belt on. The ALR mode of operation is automatically cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function). Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only, as a unique feature. Corvette customers may find this feature appealing when they plan to operate the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the operator is snugly cinched into the seat and kept firmly in place during high G-force driving maneuvers. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 6495 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Rear Seat Center Shoulder Belt Replacement Seat Belt: Service and Repair Rear Seat Center Shoulder Belt Replacement Rear Seat Center Shoulder Belt Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Rear Seat Center Shoulder Belt Replacement > Page 6498 Seat Belt: Service and Repair Seat Belt Latch Stop Installation Seat Belt Latch Stop Installation Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Rear Seat Center Shoulder Belt Replacement > Page 6499 Seat Belt: Service and Repair Driver or Passenger Seat Retractor Side Belt Replacement Driver or Passenger Seat Retractor Side Belt Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Rear Seat Center Shoulder Belt Replacement > Page 6500 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Rear Seat Center Shoulder Belt Replacement > Page 6501 Seat Belt: Service and Repair Shoulder Belt Replacement - Rear Shoulder Belt Replacement - Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 6510 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 6516 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Driver or Passenger Seat Belt Buckle Replacement Seat Belt Buckle: Service and Repair Driver or Passenger Seat Belt Buckle Replacement Driver or Passenger Seat Belt Buckle Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Driver or Passenger Seat Belt Buckle Replacement > Page 6519 Seat Belt Buckle: Service and Repair Rear Seat Buckle Side Belt Replacement Rear Seat Buckle Side Belt Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams Seat Belt Buckle Switch: Diagrams Component Connector End Views B88D Seat Belt Switch - Driver B88P Seat Belt Switch - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 6523 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Technical Service Bulletins > Restraints - Extender Availability For Seat Belt Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt INFORMATION Bulletin No.: 99-09-40-005F Date: June 23, 2010 Subject: Seat Belt Extender Availability Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2009‐2011 model years and update the Warranty Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints). Important: DO NOT use belt extenders when securing a child restraint. The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient belt length to accommodate most drivers and passengers. Consequently, requests for belt extensions (extenders) should be minimal. Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15 in). They are designed to be coupled with the existing belts in each vehicle. When in use, the extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is extremely important that the correct length extender be used for the vehicle and occupant intended. Important: Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when you cannot buckle the safety belt without using an extender. Parts Information For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada. Warranty Information ^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their specific vehicles. ^ Dealers should not be charging part costs since these extenders are supplied by GM to the dealers. ^ Dealers should not be charging labor costs since the extender can be customer installed. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair Seat Belt Guide Track: Service and Repair Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions Seat Belt Retractor: Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions INFORMATION Bulletin No.: 05-09-40-002E Date: October 21, 2010 Subject: Safety Belt Locking Conditions (Normal Operating Characteristic) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 05-09-40-002D (Section 09 - Restraints). The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are several different locking situations for both front and rear safety belts. Overspool Lock There is an unintentional locking condition that ALL safety belts from ALL manufacturers may experience called "overspool lock". If the webbing snaps back to the stowed position rapidly enough, the retractor will lock with the belt fully stowed. This is more likely to occur when customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the retractive speed of the webbing, the higher than normal webbing retraction speed that occurs engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT replace the retractor for this condition until first attempting to disengage the locking mechanism by following the recommendation listed below. Recommendation Pull hard on the locked webbing and then release. The hard pull extracts a small amount of webbing from the retractor which, in turn, permits a small amount of retraction to occur when released. This is all that is needed to disengage the locking mechanism. The safety belt will now function properly. Vehicle Sensing This type of locking occurs in response to the vehicle under the following conditions: - The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR rapid deceleration or there is aggressive cornering). - It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or side-to-side), such as streets in San Francisco, California. - It may also occur over rough road conditions where the retractor mechanism is bounced into a locked condition. In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked. When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt should return to normal function. Please inform customers that may comment that "the belt locks intermittently" that this is the design intent and the belt is functioning properly. Web Sensing This type of locking occurs in response to the extraction of webbing. When the webbing reels out at an accelerated rate, it goes into lock mode and stays there until tension is again released. To observe this condition, extract the webbing quickly. Customers may refer to this condition as "intermittent lock-up" and encounter it when trying to put the belt on too quickly. Automatic Locking (ALR) When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to the end of travel while they are putting the belt on. The ALR mode of operation is automatically cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function). Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only, as a unique feature. Corvette customers may find this feature appealing when they plan to operate the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the operator is snugly cinched into the seat and kept firmly in place during high G-force driving maneuvers. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 6535 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 6536 Seat Belt Retractor: Diagrams Component Connector End Views F112D Seat Belt Pretensioner (Retractor) - Driver F112P Seat Belt Retractor Pretensioner - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 6537 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams Seat Belt Tensioner: Diagrams Component Connector End Views F112D Seat Belt Pretensioner (Retractor) - Driver F112P Seat Belt Retractor Pretensioner - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Page 6541 F113D Seat Belt Anchor Pretensioner - Driver F113P Seat Belt Anchor Pretensioner - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Page 6542 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures Seat Belt Tensioner: Procedures Pretensioner Handling and Scrapping Scrapping Procedure During the course of a vehicles useful life, certain situations may arise which will necessitate the disposal of a live (undeployed) pretensioner. The following information covers the proper procedures for the disposing of a live (undeployed) pretensioner. Deploy the pretensioner before disposal. Do not dispose of a live (undeployed) pretensioner through normal disposal channels until the pretensioner has been deployed. The following information covers the proper procedures for the disposing of a live (undeployed) pretensioner. * After replacement of a pretensioner under warranty. The pretensioner may need to be returned undeployed to the original manufacturer of pretensioner. * If the vehicle is the subject of a Product Liability report related to the SIR system and is subject to a Preliminary Investigation (GM-1241). Do not alter the SIR system in any manner. * If the vehicle is involved in a campaign affecting the pretensioners. Follow the instructions in the Campaign Service Bulletin for proper SIR handling procedures. Deployment Procedures The pretensioner can be deployed inside or outside of the vehicle. The method used depends upon the final disposition of the vehicle. Review the following procedures in order to determine which will work best in a given situation. Deployment Inside the Vehicle Refer to Inflatable Restraint Module Handling and Scrapping (See: Air Bag Systems/Air Bag/Service and Repair/Procedures) for deploying the pretensioner inside vehicle under Vehicle Scrapping Procedure. Deployment Outside Vehicle for Seat Belt Pretensioners Deploy the seat belt pretensioners outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: * Using the SIR diagnostics, you determine that the seat belt pretensioner is malfunctioning. * The pretensioner pigtail (if equipped) is damaged. * The pretensioner connector is damaged. * The pretensioner connector terminal is damaged. Deployment and disposal of a malfunctioning seat belt pretensioner is subject to any required retention period. Warning In order to prevent accidental deployment of the pretensioner which could cause personal injury, do not dispose of an undeployed pretensioner as normal shop waste. The undeployed pretensioner contains substances that could cause severe illness or personal injury if the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed pretensioner. Failure to dispose of a pretensioner as instructed may be a violation of federal, state, or local laws. Warning When you are deploying a pretensioner for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Special Tools * J 39401-B SIR Deployment Fixture * J 38826 SIR Deployment Harness Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 6545 1. Turn the ignition switch to the OFF position. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove the seat belt pretensioner from the vehicle. 5. When carrying a pretensioner to the deployment area keep the open end of pretensioner pointed away from the body. 6. Clear a space on the ground about 1.85 M (6 ft) in diameter for deployment of the pretensioner. If possible, use a paved, outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Make sure you have sufficient ventilation. 7. Make sure no loose or flammable objects are in the area. 8. Place the J 39401-B SIR Deployment Fixture in the center of the cleared area. 9. Fill the fixture plastic reservoir with water or sand. 10. Mount the pretensioner (1) in the SIR deployment fixture (3) with the open end facing up using the following mounting method. 1. Adjust and secure the J 39401-B arms (4) to the deployment fixture (3). 2. To mount, use the proper size bolt (2) and nut (5) with washers in order to secure the pretensioner (1) to the deployment fixture brackets (4). 3. Securely tighten all fasteners prior to deployment. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 6546 11. Inspect the J 38826 SIR Deployment Harness and the appropriate pigtail adapter for damage. Replace as needed. 12. Short the 2 SIR deployment harness (1) leads together using one banana plug seated into the other. 13. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). 14. Extend the SIR deployment harness and adapter to full length from the deployment fixture. 15. Connect the pretensioner (1) to the adapter (2) on the deployment harness (3). Note: The rapid gas expansion involved with deploying a pretensioner is very loud. Notify all the people in the immediate area that you intend to deploy the seat belt pretensioner. 16. Clear the area of people. Warning Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 6547 When you are deploying a pretensioner for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. 17. Separate the 2 banana plugs on the SIR deployment harness. Note: When the seat belt pretensioner deploys, the deployment fixture may jump about 30 cm (1 ft) vertically. This is a normal reaction of the seat belt pretensioner due to the force of the rapid expansion of gas inside the pretensioner. 18. Place a 12 V minimum/2 A minimum power source (i.e., vehicle battery) near the shorted end of the harness. 19. Connect the SIR deployment harness wires to the power source. Pretensioner deployment will occur when contact is made. 20. Disconnect the SIR deployment harness from the power source after the pretensioner deploys. 21. Seat one banana plug into the other in order to short the deployment harness leads. 22. If the pretensioner did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps. 23. Put on a pair of shop gloves. 24. Disconnect the pigtail adapter from the pretensioner as soon as possible. 25. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed. 26. Dispose of the deployed pretensioner through normal refuse channels. 27. Wash hands with a mild soap. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 6548 Seat Belt Tensioner: Removal and Replacement Driver or Passenger Seat Belt Tensioner Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations Passenger Compartment/Roof Component Views Left Rear of the Passenger Compartment Components 1 of 2 1 - F105L Roof Rail Air Bag - Left 2 - B63LR Side Impact Sensor - Left Rear 3 - B5LR Wheel Speed Sensor - Left Rear 4 - G309 Panel Rear - Left 5 - G401 Panel Rear - Left Left Side of the Passenger Compartment Components Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6553 1 - B63LF Side Impact Sensor - Left Front 2 - F112D Seat Belt Retractor Pretensioner - Driver Right Rear of the Passenger Compartment Components 1 of 2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6554 1 - T3 Audio Amplifier 2 - P19AA Speaker - Right Subwoofer 3 - X1 Audio Amplifier X1 4 - X2 Audio Amplifier X2 5 - X3 Audio Amplifier X3 6 - B63RR Side Impact Sensor - Right Rear Right Side of the Passenger Compartment Components 3 of 3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6555 1 - F112P Seat Belt Retractor Pretensioner - Passenger 2 - B63RF Side Impact Sensor - Right Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6556 Impact Sensor: Diagrams Component Connector End Views B59L Front Impact Sensor - Left B59R Front Impact Sensor - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6557 B63LF Side Impact Sensor - Left Front B63LR Side Impact Sensor - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6558 B63RF Side Impact Sensor - Right Front B63RR Side Impact Sensor - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6559 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Side Impact Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement Inflatable Restraint Side Impact Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Side Impact Sensor Replacement > Page 6562 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Side Impact Sensor Replacement > Page 6563 Impact Sensor: Service and Repair Front End Inflatable Restraint Discriminating Sensor Replacement Front End Inflatable Restraint Discriminating Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams Seat Belt Buckle Switch: Diagrams Component Connector End Views B88D Seat Belt Switch - Driver B88P Seat Belt Switch - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 6567 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Inflatable Restraint Front Passenger Presence Sensor Replacement Seat Occupant Sensor: Service and Repair Inflatable Restraint Front Passenger Presence Sensor Replacement Inflatable Restraint Front Passenger Presence Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Inflatable Restraint Front Passenger Presence Sensor Replacement > Page 6574 Seat Occupant Sensor: Service and Repair Inflatable Restraint Front Passenger Presence Module Replacement Inflatable Restraint Front Passenger Presence Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Relay > Component Information > Locations Accessory Relay: Locations Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Relay > Component Information > Locations > Page 6579 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Application and ID Antenna Cable: Application and ID Antenna Coaxial/Connector Cable Identification Table Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Horn > Component Information > Service and Repair Alarm Horn: Service and Repair Theft Deterrent Alarm Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6592 Alarm Module: Diagrams Component Connector End Views K89 Immobilizer Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6593 Alarm Module: Service and Repair Theft Deterrent Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Antenna - Keyless Entry > Component Information > Service and Repair Antenna - Keyless Entry: Service and Repair Ignition Lock Key Transmitter Antenna Replacement - Floor Console Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Passenger Compartment/Roof Component Views Roof/Headliner Components 1 - B160 Windshield Temperature and Inside Moisture Sensor 2 - K84 Remote Function Receiver Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Diagrams Keyless Entry Receiver: Diagrams Component Connector End Views K77 Remote Control Door Lock Receiver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Diagrams > Page 6604 Keyless Entry Receiver: Service and Repair Remote Control Door Lock Receiver Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Transmitter: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6609 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6610 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6611 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6612 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6613 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6614 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6615 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6616 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6617 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6618 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6619 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6620 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6621 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6622 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6623 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6624 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6625 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6626 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6627 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6628 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6629 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6630 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6631 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6632 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6633 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6634 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6635 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6636 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6637 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6638 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6639 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6640 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6641 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6642 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6643 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6644 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6645 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6646 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6647 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6648 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6649 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6650 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6651 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6652 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6653 Keyless Entry Transmitter: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6654 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6655 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6656 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools EL-35616-200 - Test Light - Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A Digital Multimeter (DMM) should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The EL-35616-200 - kit is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6657 Testing for a Short to Voltage Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J-25070 - Heat Gun For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, to move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to the Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J-25070 - heat gun. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6658 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. In addition, circuit cooling spray can be used to cool down a component or circuit. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6659 For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Special Tools Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6660 EL-35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6661 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Using Snapshots in Global Diagnostic System (GDS) Overview Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6662 A snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. To record a snapshot in GDS, select, Record Snapshot, from the options at the top right portion of any of the various pages that allow snapshots to be taken (e.g. Data Display, Control Functions, etc.). When you are finished recording, select, Stop Snapshot recording. The snapshot will now be available for replay. Snapshot Replay The Snapshot Replay function allows reviews of previously recorded vehicle snapshot data. This information can be used in analysis of vehicle problems and detection of trigger error conditions. The graph function can be used to compare parameters to see if a component is functioning properly. Recorded snapshots can be selected for viewing by the following three methods: * Selecting a snapshot file from the Vehicle Home Page and clicking on the Review selection. * Double clicking on the selected snapshot from the Vehicle Home Page. * Entering the Tools selection from the Menu selection and selecting Snapshot replay. Next, open the Snapshot Manager. Double click on the snapshot file you wish to view or click on the Load Snapshot selection and select a snapshot file. Regardless of selection method, a File Loaded pop-up window will be displayed from the Snapshot Replay screen. Select OK from the pop-up window. Snapshot Play Functions There are several snapshot play functions that are used to replay recorded snapshots * The Play function is used to play the snapshot forward by clicking on this selection. A marker will move across the screen when this selection is used. All selections in this area turn grey when they are active. * The Pause function is used to pause play of the snapshot. When this selection is clicked a second time the snapshot will start playing where it left off. * The Stop function is used to stop playing the snapshot. The snapshot will start from the beginning, if Play is selected after using the Stop function. Time Control Time control is used to control the snapshot replay. This function allows selection of a specific time frame, display of different views, and control of display speed. The following functions can be selected directly under Time Control. * The Bookmark selection allows you to add a specific comment in the current display and return to this point in the future. When this option is selected, a pop-up window is displayed. Enter a bookmark name and select OK. * The Note Pad can be selected to add comments to the snapshot replay file at the current point of time. When this option is selected, a pop-up window is displayed. Enter a comment for the snapshot file and select OK. * The Load Snapshot (blue folder) opens a snapshot file and makes it ready for further analysis. This function is also available by clicking on an available snapshot file from the Snapshot Manager. * The Down Arrow displays all Time Control options when selected. Individual options can also be selected by clicking on the item you want. * The Snapshot Display Speed can be controlled by selecting this option. Slow speeds of 1/8X, 1/4X, and 1/2X can be selected. The real time speed can also be selected at 1. Faster speeds of 2X, 4X, and 8X can also be obtained by using this selection. View Selections Each View Selection provides a different way of displaying vehicle data for analysis. The following functions can be selected under Available Views: Note: The parameter name will be shown in the original language used for capture if no translation is available for the name. * Parameter List View - Displays incoming information from the snapshot file. The current value of the parameters is displayed on the screen. * Log View - Contains all the information from the snapshot file. All parameter values are listed in the order they were recorded. Specific parameters can be added or removed from a watchlist by clicking on the appropriate item. * State View - Shows the values of all parameters in a specific time frame. These values can be used for comparison with the trigger view. * Trigger View - Displays all system and user defined triggers. This function can be used when there is a combination of factors involved in a diagnostic problem. When a Trigger condition is met a caution triangle will be displayed on the screen. Triggers: * Load Triggers - Allows you to load a file containing trigger definitions. * Save Triggers - Allows you to save the trigger to your computer's hard drive. * Remove Trigger - Allows you to remove the current trigger. It will no longer be present. * Edit Trigger - Displays a pop-up window where you can modify the limits and parameters contained within a trigger. * Adds Trigger - Displays a pop-up window to configure a trigger. * DTC View - After the Play function is selected and this option is selected this function opens the list of recorded DTCs. * Line Graph View - Displays data that can be visualized against the time-axis. From this view, specific parameters can be selected for graphing by Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6663 checking the box under Selected. At the bottom of the graph there are four functions Zoom In (increase size), Zoom Out (decrease size), Bookmarks, and Pause Scrolling. Each of these functions can be accessed by clicking on them. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools EL-39200 - Digital Multimeter For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the EL-39200 - digital multimeter (DMM). This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. Note: The DMM must be used in order to perform the following procedure since the DMM can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6664 Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the DMM to the circuit. 2. Set the DMM to the V (AC) or V (DC) position. 3. Select the voltage range feature of the DMM in order to select the desired voltage range. Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 4. Select the MIN MAX function of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button until the MAX value is displayed and note the value. 8. Press the MIN MAX button until the MIN value is displayed and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools EL-35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6665 To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the EL-35616 - kit when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center. Use EL-35616 - kit to test for proper terminal contact. Failure to use EL-35616 - kit can result in improper diagnosis of the bussed electrical center. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal/terminated lead, verify that the retention force is significantly different between a known good terminal and the suspect terminal. Replace the female terminal in question. Flat Wire Connectors There are no serviceable parts for flat wire connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter into the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6666 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures - In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference or other types of electrical noise. Inspect for the following conditions: * A mis-routed harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc.-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc.-These accessories may create interference in other circuits while operating and the interference would disappear when the accessory is not operating. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6667 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, current, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 Mohm input impedance 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Current 1. Test a DC current range of 0.1 µA-10 A. 2. Test an AC current range of 0.1 µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 Mohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 Hz-199 k Hz Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6668 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 25 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the engine control module (ECM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the EL-39200. The DMM instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Special Tools EL 35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools EL 35616-20F - Fused Jumper Wire For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: A fused jumper may not protect solid state components from being damaged. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6669 The EL 35616-20F - Fused Jumper Wire includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool * J-38125-216 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6670 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6671 3. Slide the lever lock forward while pressing down on the lever lock release tab. 4. View showing depressing of the lever lock release tab. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6672 5. View of connector in released position. 6. Disconnect the connector from the component. 7. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 8. Release the rear lower half of the wiredress cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6673 9. Release the tabs that are holding the wiredress cover to the connector body. 10. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J-38125-216 can also be used to remove the nose piece. 11. Use the J-38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6674 12. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 13. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 14. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-561 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6675 4. Insert the J-38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-213 - Terminal Release Tool * J-38125-556 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6676 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6677 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6678 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J-38125-213 or the J-38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. 10. Reconnect the connector bodies. Bosch Connectors (0.64) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6679 Bosch Connectors (0.64) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6680 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6681 11. Insert the J-38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 13. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 14. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6682 Bosch Connectors (2.8 JPT) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-557 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J-38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6683 * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT) )Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock))FCI Connectors (SIR) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI (SIR)) * FEP Connectors (Steering Gear) (See: General Electrical Diagnostic Procedures/Connector Repairs/FEP Connectors (Steering Gear)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) Connector Anatomy Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6684 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6685 * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6686 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6687 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6688 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6689 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools EL-38125-580 - Terminal Release Tool Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6690 Terminal Removal Procedure Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull to Seat) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6691 Delphi Connectors (Pull To Seat) Special Tools EL-38125-580 - Terminal Release Tool Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Review the connector end view to determine the proper test probe and release tool. 5. Insert the release tool into the front of the connector body. 6. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 3. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-21 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6692 Terminal Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6693 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6694 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wire dress cover and pull the lever over and past the locks. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6695 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6696 Note: Be careful not to angle or rock the J-38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J-38125-21 tool into the round canal between the terminals cavities at the front of the connector. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6697 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6698 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6699 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6700 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J-38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6701 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-10A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J-38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6702 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (12-Way) Delphi Connectors (12-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6703 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6704 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6705 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J-38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6706 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (Steering Gear) Delphi Connectors (Steering Gear) Removal Procedure 1. Use a small flat-bladed tool to release the locking tab on the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6707 2. Push down the locking tab to release the connector. The small flat-bladed tool may need to be pushed down and angled back slightly to depress the locking tab. Pull on the connector body while releasing the locking tab to disconnect the connector. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-556 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6708 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6709 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. 7. For the larger terminals insert the J-38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J-38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6710 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 9. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 10. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. FCI (SIR) FCI Connectors (SIR) Removal Procedure Note: The orange connector position assurance (CPA) must be released first to disconnect or to connect the connector. 1. Lift the orange CPA vertically (avoid lifting on an angle to the connector) approximately 4 mm to release the connector. Use a small flat-bladed Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6711 tool to help release the orange CPA. The orange CPA can also be released manually without any tools. 2. Grab the connector on both sides and lift the connector vertically to disconnect the connector. Installation Procedure 1. Lift the orange CPA vertically approximately 4 mm before installing the connector. Use a small flat-bladed tool to help release the orange CPA. The orange CPA can also be released manually without any tools. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6712 2. Line up the connector key tabs with the initiator key slots. Grab the connector on both sides and push the connector down into the initiator connector sub assembly until fully seated. 3. After the connector is fully seated, push down the orange CPA with your thumb. Push down until the orange CPA is touching the yellow cover on the connector. FEP Connectors (Steering Gear) FEP Connectors (Steering Gear) Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6713 1. Use a small flat-bladed tool to release the locking tab on the connector. 2. Push down the locking tab to release the connector. The small flat-bladed tool may need to be pushed down and angled back slightly to depress the locking tab. Pull on the connector body while releasing the locking tab to disconnect the connector. JST Connectors JST Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6714 The JST connector family consists of seven unique connector housings differentiated by color and keying. This connector family is designed to use both 0.64 and 2.8 sized terminals. 1. While depressing the lock, remove the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6715 2. Unlock the terminal position assurance (TPA): * Position connector as shown (above) and locate TPA staging cavities. * Using connector terminal release tool J-38125-553 (1) lift the TPA into the staged position (figure 1). Perform this step on both sides of the TPA. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6716 * You will feel the TPA click into place when fully extended into the staged position. The figure above shows the TPA (1) in the staged position. 3. Release the terminal from the connector: * Position the connector as shown (above) and locate the terminal release entry canal (1) of the suspect terminal. * Insert the connector terminal release tool J-38125-553 into the entry canal with the angled side of the tool facing the connector wall containing cavity 4 (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6717 * The cavity on the left (1) is a 2.8 mm cavity and the cavity on the right (2) is a 0.64 mm cavity. * Place the tip of the connector terminal release tool onto the connector lance (3) and deflect the lance to the right (5) to release the lock. Hold this released position. * Holding the lance in the released position, slightly pull on the suspect terminal to remove it from the connector housing. The side TPA (4) is a secondary lock. 4. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 5. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-24 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6718 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6719 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6720 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6721 8. Use the J-38125-24 or the J-38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-28 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6722 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6723 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J-38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6724 locked in place by gently pulling on the wire. 3. Locate the TPA. 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6725 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-213 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6726 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6727 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6728 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J-38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6729 Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6730 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J-38125-12A - tool into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6731 7. Pressing the J-38125-12A - tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool * J-38125-13A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-bladed tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6732 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-bladed tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J-38125-13A - tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J-38125-12A - tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6733 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6734 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6735 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6736 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6737 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6738 6. Use the J-38125-12A tool to release the terminals by pressing on the tang. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool * J-38125-212 - Terminal Release Tool * J-38125-216 - Terminal Release Tool * J-38125-221 - Terminal Release Tool * J-38125-560 - Terminal Release Tool * J-38125-566 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6739 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6740 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6741 Note: During assembly the terminal position assurance (TPA) will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J-38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6742 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6743 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6744 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J-38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6745 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6746 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6747 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6748 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6749 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. 22. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 23. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool * J-38125-212 - Terminal Release Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6750 * J-38125-556 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6751 Note: Terminal position assurance (TPA) is keyed and can only be inserted in one direction. 3. Using terminal release tool J-38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6752 5. Using terminal release tool J-38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6753 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6754 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6755 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6756 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6757 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6758 * J-38125-552 - Terminal Release Tool * J-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6759 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6760 5. Once the nose piece retainers are relaxed, use the J-38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6761 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6762 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6763 2. Insert the J-38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6764 5. Insert the J-38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-24 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6765 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6766 5. While pushing the terminal forward, insert the J-38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6767 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J-38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6768 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-215 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6769 1. While depressing the lock, pull the two connector halves apart. Note: The terminal position assurance (TPA) is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the TPA towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6770 4. View of the female half of the connector with male terminals. 5. Use the J-38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. 6. View of the female half of the connector with male terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6771 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 9. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 10. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Repairing Connector Terminals (Terminated Lead Repair) Repairing Connector Terminals (Terminated Lead Repair) Special Tools * EL-38125-10 - Splice Sleeve Crimp Tool * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs procedures. For high temperature wiring repairs, refer to High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs). Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to in Splicing Copper Wire Using Splice Sleeves to identify the correct DuraSeal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Repairing Connector Terminals (Terminal Repair) Repairing Connector Terminals (Terminal Repair) Special Tools * J-38125 - Terminal Repair Kit * J-38125-6 - Crimp Tool * J-38125-7 - Crimp Tool * J-38125-8 - Crimp Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6772 * J-38125-64 - Crimp Tool * J-38125-101 - Crimp Tool * J-38125-641 - Crimp Tool * J-38125-642 - Crimp Tool * J-38125-643 - Crimp Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Use the following repair procedures to repair each type of terminal: * For push to seat terminals, refer to Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)). * For pull to seat terminals, refer to Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)). Note: The first step for all terminal repairs is to find the connector end view in SI. Cable Seal Terminals 1. Cut off the terminal between the core and the insulation crimp to minimize any wire loss. 2. Remove the old seal. 3. Apply the correct cable seal, per the wire gauge size, from the kit. Slide the seal back along the wire to enable removal of the insulation. 4. To minimize wire loss, remove only the insulation required. 5. Using the connector end view, determine the correct crimp tool and crimp jaw. 6. Align the seal with the end of the cable insulation. 7. Position the stripped wire and seal in the terminal. 8. Hand Crimp the core wings first. 9. Hand Crimp the insulation wings around the seal and the cable. 10. Solder all of the hand crimp terminals except the Micro-Pack 100 and 0.64 sizes. Unsealed Terminals 1. Cut off the terminal between the core and the insulation crimp to minimize any wire loss. 2. To minimize wire loss, remove only the insulation required. 3. Position the stripped wire in the terminal. 4. Hand Crimp the core wings first. 5. Hand Crimp the insulation wings around the cable. 6. Solder all of the hand crimp terminals except the Micro-Pack 100 and 0.64 sizes. Micro-Pack 100W Size Terminal The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6773 the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Micro 0.64 Size Terminal The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J-38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J-38125-64 crimping tool is also designed to crimp Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6774 both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6775 7. Place the terminal into the appropriate cavity and assemble the connector. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6776 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch Special Tool * DuraSeal splice sleeves * A wire stripping tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6777 For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A terminated lead can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs in the service information connector end views or the vehicle schematics in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and EL-38125-10 - tool. For wiring repair, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. High Temperature Wiring Repairs High Temperature Wiring Repairs Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6778 Note: All wiring repairs need to be 200 mm from the heat zone. Areas of consideration would be any area located near the exhaust manifolds, catalytic converter, exhaust pipes, and turbocharged engines. Items Required * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * Terminated leads or pigtails * The correct tools to remove the terminals from the connectors Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing. * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Note: High temperature areas would be areas located near exhaust manifolds, catalytic converters, exhaust pipes, and turbocharged engines. Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6779 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. Terminated leads can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs in the service information connector end views or the vehicle schematics in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6780 the DuraSeal splice sleeves and EL-38125-10 - tool. For wiring repair, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). For connector position assurance (CPA), refer to Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks). For terminal position assurance (TPA), refer to Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks). Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except Tefzel and coaxial. Use DuraSeal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert to regional wiring gauge size. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. For high temperature wiring, slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6781 tubing will not interfere with the splice procedure. 5. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 6. Use the splice sleeve crimp tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 7. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 8. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 9. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4, 6 and 15 for the opposite end of the splice. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6782 10. Using the heat torch, apply heat to the crimped area of the barrel. 11. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. High Temperature Wiring Repairs Use the following procedures to perform high temperature wiring repairs: 1. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 2. Using the heat torch, apply heat to the high temperature heat shrink tubing. 3. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 4. Replace any reflective tape and clips that may have been removed during the repair. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6783 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6784 * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6785 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6786 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6787 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. Note: Some terminals have a lever that must be disengaged before the terminal can be released. * Insert the terminal release tool into the cavity. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6788 Special Tools * EL-38125-10 - Splice Sleeve Crimp Tool * EL-38125-580 - Terminal Release Tool Kit * J-38125-5 - Ultra Torch * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6789 (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6790 Keyless Entry Transmitter: Electrical Diagrams Remote Function Schematics Keyless Entry Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Page 6791 Keyless Entry Transmitter: Tools and Equipment Special Tools Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Service and Repair Cellular Phone Microphone: Service and Repair Mobile Telephone Microphone Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Locations Communications Control Module: Locations Instrument Panel/Center Console Component Views Behind the Right Side of the I/P Components 1 of 2 1 - F105 Passenger Instrument Panel Air Bag 2 - K82 Mobile Telephone Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement Communications Control Module: Service and Repair Communication Interface Module Replacement Communication Interface Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement > Page 6801 Communications Control Module: Service and Repair Communication Interface Module Battery Replacement Communication Interface Module Battery Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement > Page 6802 Communications Control Module: Service and Repair Communication Interface Module Bracket Replacement Communication Interface Module Bracket Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement > Page 6803 Communications Control Module: Service and Repair Mobile Telephone Control Module Replacement Mobile Telephone Control Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations Parking Assist Control Module: Locations Luggage Compartment/Rear of Vehicle Component Views Left Side of the Luggage Compartment Components 1 - X2 Parking Assist Control Module X2 2 - X1 Parking Assist Control Module X1 3 - K41 Parking Assist Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 6808 Parking Assist Control Module: Diagrams Component Connector End Views K41 Parking Assist Control Module X1 (UD7) K41 Parking Assist Control Module X2 (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 6809 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 6810 Parking Assist Control Module: Service and Repair Rear Object Alarm Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations Parking Assist Distance Sensor: Locations Luggage Compartment/Rear of Vehicle Component Views Rear of the Vehicle Components 1 - B78G Rear Object Sensor - Left Outer 2 - B78E Rear Object Sensor - Left Middle 3 - B78F Rear Object Sensor - Right Middle 4 - B78H Rear Object Sensor - Right Outer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Page 6814 Parking Assist Distance Sensor: Diagrams Component Connector End Views B78E Rear Object Sensor - Left Middle (UD7) B78F Rear Object Sensor - Right Middle (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Page 6815 B78G Rear Object Sensor - Left Outer (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Page 6816 B78H Rear Object Sensor - Right Outer (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Page 6817 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Housing Replacement Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement Rear Object Sensor Housing Replacement 1. Remove the rear fascia. Refer to Rear Bumper Fascia Replacement (See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Replacement). 2. Disconnect the sensor harness. 3. Remove the sensor from the sensor housing. The sensor housing must be painted if replaced. If reinstalled, painting will not be necessary. Important: Do Not grind off alignment tabs. 4. Sand/grind sonic weld plastic residue from the fascia. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Housing Replacement > Page 6820 5. Apply structural adhesive epoxy, Lord Fusor(TM) 127EZ or equivalent, to fascia at mating surface. 6. Using the alignment tabs, install the sensor housing to the fascia. 7. Allow adhesive to cure according to manufacturer's directions. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Housing Replacement > Page 6821 8. Install the sensor to the sensor housing. 9. Connect the electrical harness. 10. Install the rear fascia. Refer to Rear Bumper Fascia Replacement (See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Housing Replacement > Page 6822 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Replacement Rear Object Sensor Replacement Removal Procedure 1. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement (See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Replacement) 2. Disconnect electrical from the rear object sensor. 3. Lift the locking tabs on the housing and remove the rear object sensor. Installation Procedure 1. Insert the sensor into the housing. 2. Connect the electrical connector to the rear object sensor. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Housing Replacement > Page 6823 3. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement (See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations Driver/Vehicle Information Display: Locations Instrument Panel/Center Console Component Views Center of the I/P Components 1 - P16 Instrument Cluster 2 - P17 Info Display Module 3 - S26 Hazard Lamps Switch 4 - A26 HVAC Control 5 - S13D Door Lock Switch - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations > Page 6827 Driver/Vehicle Information Display: Diagrams Component Connector End Views P17 Info Display Module (UAG or UFD) P17 Info Display Module (UDN) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations > Page 6828 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations > Page 6829 Driver/Vehicle Information Display: Service and Repair Driver Information Display Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 6838 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 6844 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player Auxiliary Input / Output Jack: Technical Service Bulletins Audio - Information on USB/Multimedia Player INFORMATION Bulletin No.: 10-08-44-004A Date: November 11, 2010 Subject: Information on USB Command and Control Multimedia Player Interface/List of Supported Devices Models: 2011 Buick Regal 2010-2011 Cadillac SRX 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2011 Chevrolet Cruze, Equinox, Volt 2010-2011 GMC Terrain All Equipped with Convenience and Connectivity Package (RPOs UUK, UUL, UYS) Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 10-08-44-004 (Section 08 - Body and Accessories). USB Radio and MP3 Functionality The universal serial bus (USB) will be a USB 2.0 port on the radio faceplate, on the IP or in the center console. This interface will give the customer the additional functionality of iPod(R)/MP3 command and control. Customers now have full radio control of the iPod/MP3 audio files via the USB cable. A single USB connection allows digital audio transferring from the iPod to the radio. The iPod will be charging while connected to the radio. The customer will also have playback capability with a USB memory stick (only MP3 and WMA files). Note Not all memory sticks are supported. Note Video from the iPod is NOT capable of being transferred to a Navigation radio display. Problems with iPod Not Connecting If the infotainment system does not operate properly when using a device connected through the USB port, this may be due to an incompatible media device. Important DO NOT replace the radio or multimedia interface module due to a customer device incompatibility issue. Verify the customer's media device is validated for this system using the list below. If the customer's device is a validated device for this system, follow the SI diagnostic procedure to isolate the fault. If the customer's device is not on the validated device list, explain to the customer that their particular unit is not compatible with the system. Troubleshooting Tips for iPod Devices 1. Verify the version of the iPod/MP3 to confirm that it is supported. 2. Unplug and re-insert the iPod to verify the customer concern. 3. Verify the battery charge of the iPod. A low battery condition on the iPod may not allow it to connect to the radio. The iPod may need to be charged before it can be controlled by the radio. 4. If the customer receives a "Device Not Supported" message on their radio or is having general iPod/MP3 connection issues (and they have a supported device), they may need to reset their iPod. To reset the iPod: - For the iPod nano(R) and iPod classic(R), toggle the Hold switch on and off (slide it to Hold, then turn it off again). Press and hold the Menu and Center (Select) buttons simultaneously until the Apple(R) logo appears, about 6 to 8 seconds. You may need to repeat this step. - For the iPod touch(R) and iPhone(R): Press and hold the Sleep/Wake button for a few seconds until the red slider appears, then slide the slider. 5. For iPod touch and iPhone: To obtain full use capabilities of their device, it needs to be fully powered up when connecting to the USB port. If these devices are fully powered down or in "sleep" mode, please advise the customer to press and hold the Sleep/Wake button on the top of the device for a few seconds and if an unlock pass code is required, to enter the pass code as well as slide the lower "Unlock" slider. 6. Have the customer inspect their cable for quality. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 6850 - Aftermarket cables can wear from use. The customer may need to purchase a new USB cable. - Verify that cable extensions are not present. The extra capacitance may cause too large a signal drop for the iPod to communicate with the radio. 7. If the customer receives a "Device Not Supported" message on their radio with an iPod connected (and they have a supported device), the customer may need to download the latest firmware from the Apple website (Please visit www.apple.com for more information). Validated Apple Device - Both Charge/Support Digital Audio Important None of these device lists below support video. Important Not all iPhone functions are fully supported. For further information on identifying iPod models, please visit http://support.apple.com/kb/HT1353. Important These devices (and additional MP3 players) may be capable of connecting to the other USB options by internally setting the MP3 device to mass storage class (MSC) mode. In this mode, the USB port will see the device as a flash drive. Please have the customer refer to their MP3 device manual on how to set the device to MSC. If the device is not able to be set to MSC, the customer must use the AUX jack. Note MTP mode must be used in order to transfer ANY Digital Rights Management (DRM) protected content. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 6851 Non-Validated Apple Device Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 6852 Playback Operation (X = Supported; - = Not Supported) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 6853 Other USB Device Supported Requirements (X = Supported; - = Not Supported) Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 6854 Auxiliary Input / Output Jack: Technical Service Bulletins Audio System - USB/Multimedia Interface Information INFORMATION Bulletin No.: 09-08-44-013C Date: October 05, 2010 Subject: Information on USB Command and Control Multimedia Player Interface/List of Supported Devices Models: 2010-2011 Buick Enclave, LaCrosse 2008-2011 Cadillac CTS 2010-2011 Cadillac Escalade Models, SRX 2009-2010 Chevrolet Cobalt 2009-2011 Chevrolet HHR, Malibu 2010-2011 Chevrolet Avalanche, Camaro, Equinox, Silverado, Suburban, Tahoe, Traverse 2011 Chevrolet Cruze 2010-2011 GMC Acadia, Sierra, Terrain, Yukon 2009-2010 Pontiac G5, G6, Solstice, Solstice Coupe 2009-2010 Saturn AURA, SKY 2010 Saturn OUTLOOK All Equipped with Convenience and Connectivity Package - RPOs KTA, KTB, SRJ, U4H, UUI, UUJ, UUM, UUN, U2S, U2X, U2Y, UAV, UYZ, UY5 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-44-013B (Section 08 - Body and Accessories). USB Radio and MP3 Functionality The USB (Universal Serial Bus) will be a USB 2.0 port on the radio faceplate, on the IP or in the center console. This interface will give the customer the additional functionality of iPod/MP3 command and control. Customers now have full radio control of the iPod/MP3 audio files via the USB cable. A single USB connection allows digital audio transferring from the iPod to the radio. The customer will also have playback capability with a USB memory stick (only MP3 and WMA files). Note Not all memory sticks are supported. Customers have full radio control of the iPod/MP3 audio files via the USB cable. A single USB connection allows digital audio transferring from the iPod to the radio. The iPod will be charging while connected to the radio. Note Video from the iPod is NOT capable of being transferred to a Navigation radio display. For the Chevrolet Cobalt, HHR and Malibu; Pontiac G5, G6, Solstice; and Saturn AURA, SKY, the USB port is on the faceplate of the radio. For all other models, it is located in the center console or IP. For the Cadillac CTS only, a special iPod cable (USB and AUX cable) is needed. This special cable comes delivered with the vehicle. In all cases, the iPod will be charging while connected to the radio through the USB port when the vehicle is running or the RPA is active. Problems with iPod Not Connecting If the infotainment system does not operate properly when using a device connected through the USB port, this may be due to an incompatible media device. Important DO NOT replace the radio or multimedia interface module due to a customer device incompatibility issue. Verify the customer's media device is validated for this system using the list below. If the customer's device is a validated device for this system, follow the SI diagnostic procedure to isolate the fault. If the customer's device is not on the validated device list, explain to the customer that their particular unit is not compatible with the system. Troubleshooting Tips for iPod Devices Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 6855 1. Check the version of the iPod/MP3 to confirm that it is supported. 2. Unplug and Re-insert the iPod to verify the customer complaint. 3. Verify the battery charge of the iPod. A low battery condition on the iPod may not allow it to connect to the radio. The iPod may need to be charged before it can be controlled by the radio. 4. If the customer receives a "Device Not Supported" message on their radio or is having general iPod/MP3 connection issues (and they have a supported device), they may need to reset their iPod. To reset the iPod: - For the iPod Nanos and Classic , Toggle the Hold switch on and off. (Slide it to Hold, then turn it off again. Press and hold the Menu and Center (Select) buttons simultaneously until the Apple logo appears, about 6 to 8 seconds. You may need to repeat this step. - For the iPod Touch and iPhone: Press and hold the Sleep/Wake button for a few seconds until the red slider appears, then slide the slider. 5. Have the customer check their cable for quality. - Aftermarket cables can wear from use. The customer may need to purchase a new USB cable. - Verify that cable extensions are not present. The extra capacitance may cause too large a signal drop for the iPod to communicate with the radio. 6. If the customer receives a "Device Not Supported" message on their radio with an iPod connected (and they have a supported device), the customer may need to download the latest firmware from the Apple website (Please visit www.apple.com for more information). Validated Apple Device - Both Charge/Support Digital Audio (For All RPOs) For further information on identifying iPod models, please visit http://support.apple.com/kb/ht1353 Other Validated Device- Both Charge/Support Digital Audio for Buick LaCrosse, Chevrolet Camaro, Equinox Only (RPO KTA or KTB) Important: Must be set to MTP (Mass Transfer Protocol) in the MP3 Player device setting. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 6856 Important These devices (and additional MP3 players) may be capable of connecting to the other USB options by internally setting the MP3 device to MSC (Mass Storage Class) mode. In this mode, the USB port will see the device as a flash drive. Please have the customer refer to their MP3 device manual on how to set the device to MSC. If the device is not able to be set to MSC, the customer must use the AUX jack. Note MTP mode must be used in order to transfer ANY Digital Rights Management (DRM) protected content. Non-Validated Apple Device Important The devices above are NOT supported by USB interface. Apple does not support digital media transfer from these devices through the USB port. The customer can still listen to their older iPod on vehicle by connecting it to the Auxiliary Input Jack using a standard 3.5 mm (1/8 in) stereo cable. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 6857 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Page 6858 Auxiliary Input / Output Jack: Diagrams Component Connector End Views X83 Auxiliary Audio Input Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Page 6859 Auxiliary Input / Output Jack: Service and Repair USB Receptacle Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Diagrams Entertainment System Control Module: Diagrams Component Connector End Views T11 Multimedia Interface Module (KTA) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Diagrams > Page 6863 Entertainment System Control Module: Service and Repair Multimedia Player Interface Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Global Positioning System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 6872 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Global Positioning System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 6878 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 6887 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 6893 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10-08-44-006 > Oct > 10 > Navigation - Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10-08-44-006 > Oct > 10 > Navigation Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Sensor > Component Information > Locations Pedal Positioning Sensor: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Sensor > Component Information > Locations > Page 6907 Pedal Positioning Sensor: Diagrams Component Connector End Views B22 Brake Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Sensor > Component Information > Service and Repair > Brake Pedal Position Sensor Calibration Pedal Positioning Sensor: Service and Repair Brake Pedal Position Sensor Calibration Brake Pedal Position Sensor Calibration Calibration Criteria Note: Do not apply the brake pedal during the brake pedal position sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the brake pedal position sensor calibration must be repeated. Brake pedal position sensor calibration must be performed after the brake pedal position sensor or body control module (BCM) have been serviced. The calibration procedure will set the brake pedal position sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. Calibration Procedure 1. Apply the parking brake. 2. Place the transmission in the PARK position. 3. Install a scan tool. 4. Navigate to the Module Diagnosis menu. 5. Clear all BCM DTCs before proceeding. 6. Navigate to the Configuration/Reset Functions menu of the BCM. 7. Select Brake Pedal Position Sensor Learn. 8. Select the Brake Pedal Position Sensor Learn procedure and follow the directions displayed on the screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Sensor > Component Information > Service and Repair > Brake Pedal Position Sensor Calibration > Page 6910 Pedal Positioning Sensor: Service and Repair Brake Pedal Position Sensor Replacement Brake Pedal Position Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair Amplifier: Service and Repair Radio Speaker Amplifier Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Service and Repair > Procedures Compact Disc Player (CD): Procedures Compact Disc Care and Cleaning Care of CDs Handle CDs carefully. Store them in their original cases or other protective cases and away from direct sunlight and dust. The CD player scans the bottom surface of the disc. If the surface of a CD is damaged, such as cracked, broken, scratched, or wrinkled labeling, the CD will not play properly or not at all. If the surface of a CD is soiled, take a soft, lint free cloth or dampen a clean, soft cloth in a mild, neutral detergent solution mixed with water, and clean it. Make sure the wiping process starts from the center to the edge. Do not touch the bottom side of a CD while handling it. This could damage the surface. Pick up CDs by grasping the outer edges or the edge of the hole and the outer edge. Care of CD Player The use of CD lens cleaners for CD players is not advised, due to the risk of contaminating the internal lens of the CD optics with lubricants. Stuck CDs Interrupting the battery power by pulling the fuse will sometimes release a stuck CD. If a CD is stuck, and removed, inspect it for warps, cracks, etc. If the CD is damaged, do not replace the radio. Labelling CDs Paper labels can eventually warp and wrinkle, and this will cause the disc to jam inside the CD player. Try labeling the top of the discs with a soft magic marker instead. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Service and Repair > Procedures > Page 6919 Compact Disc Player (CD): Removal and Replacement Audio Disc Player Receptacle Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams Radio/Stereo: Diagrams Component Connector End Views A11 Radio X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Page 6923 A11 Radio X2 (UDN) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Page 6924 A22 Radio Controls (UAG or UFD) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Page 6925 A22 Radio Controls (UDN) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Page 6926 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Service and Repair > Radio Control Module Replacement Radio/Stereo: Service and Repair Radio Control Module Replacement Radio Control Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Service and Repair > Radio Control Module Replacement > Page 6929 Radio/Stereo: Service and Repair Radio Replacement Radio Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Service and Repair > Radio Control Module Replacement > Page 6930 Radio/Stereo: Service and Repair Radio Control Switch Replacement - Steering Wheel Radio Control Switch Replacement - Steering Wheel Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams Speaker: Diagrams Component Connector End Views P19B Speaker - Center Instrument Panel P19AA Speaker - Right Subwoofer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 6934 P19G Speaker - Left Front P19H Speaker - Left Front Tweeter (UQA) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 6935 P19K Speaker - Left Rear P19N Speaker - Left Subwoofer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 6936 P19U Speaker - Right Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 6937 P19V Speaker - Right Front Tweeter (UQA) P19X Speaker - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 6938 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Radio Front Side Door Speaker Grille Bezel Replacement Speaker: Service and Repair Radio Front Side Door Speaker Grille Bezel Replacement Radio Front Side Door Speaker Grille Bezel Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Radio Front Side Door Speaker Grille Bezel Replacement > Page 6941 Speaker: Service and Repair Radio Front Side Door Speaker Replacement Radio Front Side Door Speaker Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Radio Front Side Door Speaker Grille Bezel Replacement > Page 6942 Speaker: Service and Repair Radio Front Speaker Replacement Radio Front Speaker Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Radio Front Side Door Speaker Grille Bezel Replacement > Page 6943 Speaker: Service and Repair Radio Rear Side Door Speaker Grille Bezel Replacement Radio Rear Side Door Speaker Grille Bezel Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Radio Front Side Door Speaker Grille Bezel Replacement > Page 6944 Speaker: Service and Repair Radio Front Side Door Speaker Grille Bezel Replacement Radio Front Side Door Speaker Grille Bezel Replacement Radio Front Side Door Speaker Replacement Radio Front Side Door Speaker Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Radio Front Side Door Speaker Grille Bezel Replacement > Page 6945 Radio Front Speaker Replacement Radio Front Speaker Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Radio Front Side Door Speaker Grille Bezel Replacement > Page 6946 Radio Rear Side Door Speaker Grille Bezel Replacement Radio Rear Side Door Speaker Grille Bezel Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Radio Front Side Door Speaker Grille Bezel Replacement > Page 6947 Radio Rear Side Door Speaker Replacement Radio Rear Side Door Speaker Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Radio Front Side Door Speaker Grille Bezel Replacement > Page 6948 Radio Rear Compartment Speaker Replacement Radio Rear Compartment Speaker Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Radio Front Side Door Speaker Grille Bezel Replacement > Page 6949 Radio Windshield Side Garnish Molding Speaker Replacement Radio Windshield Side Garnish Molding Speaker Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Radio Front Side Door Speaker Grille Bezel Replacement > Page 6950 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Relay > Component Information > Locations Accessory Relay: Locations Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Relay > Component Information > Locations > Page 6955 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6959 Alarm Module: Diagrams Component Connector End Views K89 Immobilizer Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6960 Alarm Module: Service and Repair Theft Deterrent Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Locations Communications Control Module: Locations Instrument Panel/Center Console Component Views Behind the Right Side of the I/P Components 1 of 2 1 - F105 Passenger Instrument Panel Air Bag 2 - K82 Mobile Telephone Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement Communications Control Module: Service and Repair Communication Interface Module Replacement Communication Interface Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement > Page 6966 Communications Control Module: Service and Repair Communication Interface Module Battery Replacement Communication Interface Module Battery Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement > Page 6967 Communications Control Module: Service and Repair Communication Interface Module Bracket Replacement Communication Interface Module Bracket Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement > Page 6968 Communications Control Module: Service and Repair Mobile Telephone Control Module Replacement Mobile Telephone Control Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 6977 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 6983 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams Entertainment System Control Module: Diagrams Component Connector End Views T11 Multimedia Interface Module (KTA) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Page 6987 Entertainment System Control Module: Service and Repair Multimedia Player Interface Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Passenger Compartment/Roof Component Views Roof/Headliner Components 1 - B160 Windshield Temperature and Inside Moisture Sensor 2 - K84 Remote Function Receiver Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations Parking Assist Control Module: Locations Luggage Compartment/Rear of Vehicle Component Views Left Side of the Luggage Compartment Components 1 - X2 Parking Assist Control Module X2 2 - X1 Parking Assist Control Module X1 3 - K41 Parking Assist Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 6994 Parking Assist Control Module: Diagrams Component Connector End Views K41 Parking Assist Control Module X1 (UD7) K41 Parking Assist Control Module X2 (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 6995 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 6996 Parking Assist Control Module: Service and Repair Rear Object Alarm Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7005 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7006 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7007 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7013 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7014 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7015 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7024 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7025 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7026 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 7032 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 7033 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 7034 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations Parking Assist Distance Sensor: Locations Luggage Compartment/Rear of Vehicle Component Views Rear of the Vehicle Components 1 - B78G Rear Object Sensor - Left Outer 2 - B78E Rear Object Sensor - Left Middle 3 - B78F Rear Object Sensor - Right Middle 4 - B78H Rear Object Sensor - Right Outer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Page 7039 Parking Assist Distance Sensor: Diagrams Component Connector End Views B78E Rear Object Sensor - Left Middle (UD7) B78F Rear Object Sensor - Right Middle (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Page 7040 B78G Rear Object Sensor - Left Outer (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Page 7041 B78H Rear Object Sensor - Right Outer (UD7) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Page 7042 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Housing Replacement Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement Rear Object Sensor Housing Replacement 1. Remove the rear fascia. Refer to Rear Bumper Fascia Replacement (See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Replacement). 2. Disconnect the sensor harness. 3. Remove the sensor from the sensor housing. The sensor housing must be painted if replaced. If reinstalled, painting will not be necessary. Important: Do Not grind off alignment tabs. 4. Sand/grind sonic weld plastic residue from the fascia. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Housing Replacement > Page 7045 5. Apply structural adhesive epoxy, Lord Fusor(TM) 127EZ or equivalent, to fascia at mating surface. 6. Using the alignment tabs, install the sensor housing to the fascia. 7. Allow adhesive to cure according to manufacturer's directions. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Housing Replacement > Page 7046 8. Install the sensor to the sensor housing. 9. Connect the electrical harness. 10. Install the rear fascia. Refer to Rear Bumper Fascia Replacement (See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Housing Replacement > Page 7047 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Replacement Rear Object Sensor Replacement Removal Procedure 1. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement (See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Replacement) 2. Disconnect electrical from the rear object sensor. 3. Lift the locking tabs on the housing and remove the rear object sensor. Installation Procedure 1. Insert the sensor into the housing. 2. Connect the electrical connector to the rear object sensor. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Housing Replacement > Page 7048 3. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement (See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Locations Pedal Positioning Sensor: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Locations > Page 7052 Pedal Positioning Sensor: Diagrams Component Connector End Views B22 Brake Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Service and Repair > Brake Pedal Position Sensor Calibration Pedal Positioning Sensor: Service and Repair Brake Pedal Position Sensor Calibration Brake Pedal Position Sensor Calibration Calibration Criteria Note: Do not apply the brake pedal during the brake pedal position sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the brake pedal position sensor calibration must be repeated. Brake pedal position sensor calibration must be performed after the brake pedal position sensor or body control module (BCM) have been serviced. The calibration procedure will set the brake pedal position sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. Calibration Procedure 1. Apply the parking brake. 2. Place the transmission in the PARK position. 3. Install a scan tool. 4. Navigate to the Module Diagnosis menu. 5. Clear all BCM DTCs before proceeding. 6. Navigate to the Configuration/Reset Functions menu of the BCM. 7. Select Brake Pedal Position Sensor Learn. 8. Select the Brake Pedal Position Sensor Learn procedure and follow the directions displayed on the screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Service and Repair > Brake Pedal Position Sensor Calibration > Page 7055 Pedal Positioning Sensor: Service and Repair Brake Pedal Position Sensor Replacement Brake Pedal Position Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Locations Steering Mounted Controls Transmitter: Locations Instrument Panel/Center Console Component Views Top of the Steering Column Components 1 - S70R Steering Wheel Controls Switch - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Locations > Page 7059 Steering Mounted Controls Transmitter: Diagrams Component Connector End Views S70R Steering Wheel Controls Switch - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Recalls: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Body Control Module: Recalls Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Recalls: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 7070 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Recalls: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 7071 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement Body Control Module: All Technical Service Bulletins Campaign - Brake Apply Sensor Replacement SERVICE UPDATE Bulletin No.: 10317 Date: October 11, 2010 Subject: 10317 - Service Update for Inventory and Customer Vehicles - Malfunction Indicator Lamp (MIL) - Brake Apply Sensor (BAS) Replacement - Expires with Base Warranty Models: 2011 Chevrolet Cruze Equipped with Automatic Transmission This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. It will expire at the end of the involved vehicle's New Vehicle Limited Warranty period. Purpose This bulletin provides a service procedure to replace the brake apply sensor (BAS) on certain 2011 model year Chevrolet Cruze vehicles equipped with an automatic transmission. These vehicles may have been built with a BAS that may not function properly, indicated by the illumination of the malfunction indicator lamp. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility. Parts Information Parts required to complete this service update are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN 22769186, sensor, will not be eligible for RIM. Service Procedure 1. Adjust the driver's seat to the rear position. 2. Locate the brake pedal assembly. 3. Remove the brake apply sensor (BAS). 1. Disconnect the electrical wiring harness from the switch. While holding the connector, on the harness, press the connector down. Pull on the harness to remove it from the vehicle. Note Do NOT loosen the screw to remove the BAS. Tighten the screw to a torque greater than 8 Nm(71 lb in). The screw head will break off. Discard the screw head. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 7077 2. Remove the BAS screw. 3. Slide the BAS to the left to remove it from anti rotation pin. 4. Discard the BAS. Note The new BAS, P/N 22769186, is white. 4. Install a new BAS. 1. Slide the BAS from the left to right position on the brake pedal assembly. 2. Make sure that the fork (1) is aligned with the pin on the brake assembly. 3. Line up the screw (2) to the BAS hole and then fasten. Tighten the screw to 3 Nm(27 lb in). 5. Perform a Brake Pedal Position Sensor Calibration. Note Do not apply the brake pedal during the brake pedal position (BPP) sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the sensor calibration must be repeated. Brake pedal position (BPP) sensor calibration must be performed after the BAS switch or body control module (BCM) have been serviced. The calibration procedure will set the sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. 1. Apply and slowly release the brake pedal two times. 2. Apply the parking brake. 3. Place the transmission gear selector in the "P" PARK position. 4. Connect MDI and GDS. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10317 > Oct > 10 > Campaign - Brake Apply Sensor Replacement > Page 7078 5. Clear all BCM diagnostic trouble codes (DTCs). 6. Navigate to the Vehicle Control Systems menu. 7. Select Module Setup menu item. 8. Select BCM menu item. 9. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen 6. Perform ECM BAS Home Learn Procedure. 1. Put the ignition key in the RUN position (no crank). 2. Apply and slowly release the brake pedal two times and then wait 2 seconds. 3. Repeat Step 6.2 eight times. Warranty Transaction Information Submit a claim using the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7084 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7085 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7086 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7091 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7092 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7093 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7094 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7095 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7096 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 7101 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7107 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7108 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7109 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7114 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7115 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7116 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7117 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7118 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7119 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 7124 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 7125 Body Control Module: Locations Instrument Panel/Center Console Component Views Behind the Center of the I/P Components 1 of 4 1 - K9 Body Control Module 2 - X7 Body Control Module X7 3 - X6 Body Control Module X6 4 - X5 Body Control Module X5 5 - X4 Body Control Module X4 6 - X3 Body Control Module X3 7 - X2 Body Control Module X2 8 - X1 Body Control Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 7126 Body Control Module: Diagrams Component Connector End Views K9 Body Control Module X1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 7127 K9 Body Control Module X2 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 7128 K9 Body Control Module X3 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 7129 K9 Body Control Module X4 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 7130 K9 Body Control Module X5 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 7131 K9 Body Control Module X6 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 7132 K9 Body Control Module X7 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 7133 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Body Control Module Replacement Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Body Control Module Replacement > Page 7136 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia Air Deflector Actuator Replacement Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Air Deflector Actuator Replacement Front Bumper Fascia Air Deflector Actuator Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia Air Deflector Actuator Replacement > Page 7143 Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Opening Lower Cover Replacement Front Bumper Fascia Opening Lower Cover Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia Air Deflector Actuator Replacement > Page 7144 Front Bumper Cover / Fascia: Service and Repair Front Bumper Lower Fascia Bracket Replacement Front Bumper Lower Fascia Bracket Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia Air Deflector Actuator Replacement > Page 7145 Front Bumper Cover / Fascia: Service and Repair Front Bumper Lower Fascia Center Grille Replacement Front Bumper Lower Fascia Center Grille Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia Air Deflector Actuator Replacement > Page 7146 Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Air Deflector Actuator Replacement Front Bumper Fascia Air Deflector Actuator Replacement Front Bumper Fascia Opening Lower Cover Replacement Front Bumper Fascia Opening Lower Cover Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia Air Deflector Actuator Replacement > Page 7147 Front Bumper Lower Fascia Bracket Replacement Front Bumper Lower Fascia Bracket Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia Air Deflector Actuator Replacement > Page 7148 Front Bumper Lower Fascia Center Grille Replacement Front Bumper Lower Fascia Center Grille Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia Air Deflector Actuator Replacement > Page 7149 Front Bumper Lower Fascia Grille Replacement Front Bumper Lower Fascia Grille Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia Air Deflector Actuator Replacement > Page 7150 Front Bumper Fascia Guide Replacement Front Bumper Fascia Guide Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia Air Deflector Actuator Replacement > Page 7151 Front Bumper Fascia Outer Bracket Replacement Front Bumper Fascia Outer Bracket Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia Air Deflector Actuator Replacement > Page 7152 Front Bumper Fascia Replacement Front Bumper Fascia Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia Air Deflector Actuator Replacement > Page 7153 Front Bumper Fascia Air Deflector Replacement Front Bumper Fascia Air Deflector Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia Air Deflector Actuator Replacement > Page 7154 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Front Bumper Energy Absorber Replacement Front Bumper Reinforcement: Service and Repair Front Bumper Energy Absorber Replacement Front Bumper Energy Absorber Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Front Bumper Energy Absorber Replacement > Page 7159 Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Replacement Front Bumper Impact Bar Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning . Warning: Refer to Glass and Sheet Metal Handling Warning . 1. Disable the SIR System. Refer to SIR Disabling and Enabling . 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . 3. Remove all related panels and components. 4. Remove the 8 front bumper impact bar bolts (1). 5. Cut the front bumper impact bar left and right. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Front Bumper Energy Absorber Replacement > Page 7160 6. Locate and mark all factory welds. 7. Drill all factory welds. 8. Remove the remaining parts of the front bumper impact bar. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Front Bumper Energy Absorber Replacement > Page 7161 1. Position the front bumper impact bar on the vehicle. Caution: Refer to Fastener Caution . 2. Install the 8 front bumper impact bar bolts (1) and tighten to 110 Nm (81 lb ft). Note: Use only the original front bumper impact bar bolts. Replace bolts if damaged. 3. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems (). 4. Install all related panels and components. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . 6. Enable the SIR system. Refer to SIR Disabling and Enabling . Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia Bracket Replacement - Outer Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia Bracket Replacement Outer Rear Bumper Fascia Bracket Replacement - Outer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia Bracket Replacement - Outer > Page 7167 Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia Guide Replacement Rear Bumper Fascia Guide Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia Bracket Replacement - Outer > Page 7168 Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia Inner Guide Replacement Rear Bumper Fascia Inner Guide Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia Bracket Replacement - Outer > Page 7169 Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia Outer Guide Replacement Rear Bumper Fascia Outer Guide Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia Bracket Replacement - Outer > Page 7170 Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia Replacement Rear Bumper Fascia Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair Rear Bumper Reinforcement: Service and Repair Rear Bumper Impact Bar Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Adjustments Front Door Exterior Handle: Adjustments Front Side Door Outside Handle Rod Adjustment Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Front Side Door Outside Handle Bracket Replacement Front Door Exterior Handle: Service and Repair Front Side Door Outside Handle Bracket Replacement Front Side Door Outside Handle Bracket Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Front Side Door Outside Handle Bracket Replacement > Page 7187 Front Door Exterior Handle: Service and Repair Front Side Door Outside Handle Replacement Front Side Door Outside Handle Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Front Side Door Outside Handle Bracket Replacement > Page 7188 Front Door Exterior Handle: Service and Repair Front Side Door Outside Handle Rod Replacement Front Side Door Outside Handle Rod Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Handle Switch > System Information > Locations Front Door Handle Switch: Locations Door Component Views Left Rear Passenger Side Door Components 1 - B27LR Door Handle Switch - Left Rear 2 - S79LR Window Switch - Left Rear 3 - M74LR Window Motor - Left Right Rear Passenger Side Door Components Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Handle Switch > System Information > Locations > Page 7192 1 - S79RR Window Switch - Right Rear 2 - B27RR Door Handle Switch - Right Rear 3 - M74RR Window Motor - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair Front Door Interior Handle: Service and Repair Front Side Door Inside Handle Cable Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair Front Door Hinge: Service and Repair Front Side Door Upper Hinge and Lower Hinge Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams Front Door Latch: Diagrams Component Connector End Views A23D Door Latch Assembly - Driver A23LR Door Latch Assembly - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams > Page 7202 A23P Door Latch Assembly - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams > Page 7203 A23RR Door Latch Assembly - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams > Page 7204 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams > Page 7205 Front Door Latch: Service and Repair Front Side Door Latch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Limiter > System Information > Service and Repair Front Door Limiter: Service and Repair Front Side Door Check Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Trim Replacement Front Door Panel: Service and Repair Front Side Door Trim Replacement Front Side Door Trim Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Trim Replacement > Page 7213 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Trim Replacement > Page 7214 Front Door Panel: Service and Repair Front Side Door Upper Trim Cover Replacement Front Side Door Upper Trim Cover Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Trim Replacement > Page 7215 Front Door Panel: Service and Repair Front Side Door Window Switch Bezel Replacement Front Side Door Window Switch Bezel Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Trim Replacement > Page 7216 Front Door Panel: Service and Repair Front Side Door Water Deflector Replacement Front Side Door Water Deflector Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair Front Door Striker: Service and Repair Front Side Door Lock Striker Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front or Rear Side Door Lower Weatherstrip Replacement Front Door Weatherstrip: Service and Repair Front or Rear Side Door Lower Weatherstrip Replacement Front or Rear Side Door Lower Weatherstrip Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front or Rear Side Door Lower Weatherstrip Replacement > Page 7224 Front Door Weatherstrip: Service and Repair Front Side Door Weatherstrip Replacement - Door Side Front Side Door Weatherstrip Replacement - Door Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front or Rear Side Door Lower Weatherstrip Replacement > Page 7225 Front Door Weatherstrip: Service and Repair Front Side Door Weatherstrip Replacement - Body Side Front Side Door Weatherstrip Replacement - Body Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front or Rear Side Door Lower Weatherstrip Replacement > Page 7226 Front Door Weatherstrip: Service and Repair Front Side Door Window Weatherstrip Replacement Front Side Door Window Weatherstrip Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Front Door Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Page 7231 Front Door Window Glass: Service and Repair Front Side Door Window Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair Front Side Door Window Regulator Motor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Rear Side Door Outside Handle Bracket Replacement Rear Door Exterior Handle: Service and Repair Rear Side Door Outside Handle Bracket Replacement Rear Side Door Outside Handle Bracket Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Rear Side Door Outside Handle Bracket Replacement > Page 7244 Rear Door Exterior Handle: Service and Repair Rear Side Door Outside Handle Replacement Rear Side Door Outside Handle Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Rear Side Door Outside Handle Bracket Replacement > Page 7245 Rear Door Exterior Handle: Service and Repair Rear Side Door Outside Handle Rod Adjustment Rear Side Door Outside Handle Rod Adjustment Removal Procedure 1. Remove the rear door water deflector as needed. Refer to Rear Side Door Water Deflector Replacement (See: Rear Door Panel/Service and Repair/Rear Side Door Water Deflector Replacement). 2. Use a flat-bladed tool to open the clip on the threaded rod connecting the lock to the outside handle. 3. Adjust the travel of the handle by removing the threaded rod from the clip. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Rear Side Door Outside Handle Bracket Replacement > Page 7246 1. Position the outside door handle rod (2) in the clip (1) to eliminate any free play in the outside door handle. 2. Close the clip cover over the threaded outside door handle rod. 3. Inspect the door lock system for proper operation. 4. Install the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement (See: Rear Door Panel/Service and Repair/Rear Side Door Water Deflector Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Rear Side Door Outside Handle Bracket Replacement > Page 7247 Rear Door Exterior Handle: Service and Repair Rear Side Door Outside Handle Rod Replacement Rear Side Door Outside Handle Rod Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Handle Switch > System Information > Locations Rear Door Handle Switch: Locations Door Component Views Left Rear Passenger Side Door Components 1 - B27LR Door Handle Switch - Left Rear 2 - S79LR Window Switch - Left Rear 3 - M74LR Window Motor - Left Right Rear Passenger Side Door Components Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Handle Switch > System Information > Locations > Page 7251 1 - S79RR Window Switch - Right Rear 2 - B27RR Door Handle Switch - Right Rear 3 - M74RR Window Motor - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair Rear Door Interior Handle: Service and Repair Rear Side Door Inside Handle Cable Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair Rear Door Hinge: Service and Repair Rear Side Door Upper Hinge and Lower Hinge Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams Rear Door Latch: Diagrams Component Connector End Views A23D Door Latch Assembly - Driver A23LR Door Latch Assembly - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams > Page 7261 A23P Door Latch Assembly - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams > Page 7262 A23RR Door Latch Assembly - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams > Page 7263 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams > Page 7264 Rear Door Latch: Service and Repair Rear Side Door Latch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Service and Repair Rear Door Limiter: Service and Repair Rear Side Door Check Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Trim Replacement Rear Door Panel: Service and Repair Rear Side Door Trim Replacement Rear Side Door Trim Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Trim Replacement > Page 7272 Rear Door Panel: Service and Repair Rear Side Door Water Deflector Replacement Rear Side Door Water Deflector Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Trim Replacement > Page 7273 Rear Door Panel: Service and Repair Rear Side Door Window Switch Bezel Replacement Rear Side Door Window Switch Bezel Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair Rear Door Striker: Service and Repair Rear Side Door Lock Striker Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Side Door Weatherstrip Replacement - Body Side Rear Door Weatherstrip: Service and Repair Rear Side Door Weatherstrip Replacement - Body Side Rear Side Door Weatherstrip Replacement - Body Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Side Door Weatherstrip Replacement - Body Side > Page 7281 Rear Door Weatherstrip: Service and Repair Rear Side Door Weatherstrip Replacement - Door Side Rear Side Door Weatherstrip Replacement - Door Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Side Door Weatherstrip Replacement - Body Side > Page 7282 Rear Door Weatherstrip: Service and Repair Rear Side Door Window Weatherstrip Replacement Rear Side Door Window Weatherstrip Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Side Door Weatherstrip Replacement - Body Side > Page 7283 Rear Door Weatherstrip: Service and Repair Front or Rear Side Door Lower Weatherstrip Replacement Front or Rear Side Door Lower Weatherstrip Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair Rear Door Window Glass Weatherstrip: Service and Repair Rear Side Door Window Channel Insulator Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair Rear Door Window Motor: Service and Repair Rear Side Door Window Regulator Motor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair Fuel Door: Service and Repair Fuel Tank Filler Door Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair Hood Hinge: Service and Repair Hood Hinge Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Insulator / Pad > Component Information > Service and Repair Hood Insulator / Pad: Service and Repair Hood Insulator Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair Hood Latch: Service and Repair Hood Primary and Secondary Latch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Primary Latch Release Cable Replacement Hood Latch Release Cable: Service and Repair Hood Primary Latch Release Cable Replacement Hood Primary Latch Release Cable Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Primary Latch Release Cable Replacement > Page 7311 Hood Latch Release Cable: Service and Repair Hood Primary Latch Release Cable Handle Replacement Hood Primary Latch Release Cable Handle Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair Hood Shock / Support: Service and Repair Hood Hold-Open Rod Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Ajar Switch > Component Information > Diagrams Hood Ajar Switch: Diagrams Component Connector End Views B55 Hood Ajar Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair Hood Weatherstrip: Service and Repair Hood Rear Weatherstrip Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair > Rear Compartment Lid Rear Hinge Replacement Trunk / Liftgate Hinge: Service and Repair Rear Compartment Lid Rear Hinge Replacement Rear Compartment Lid Rear Hinge Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair > Rear Compartment Lid Rear Hinge Replacement > Page 7327 Trunk / Liftgate Hinge: Service and Repair Rear Compartment Lid Hinge Torque Rod Replacement Rear Compartment Lid Hinge Torque Rod Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Diagrams Trunk / Liftgate Latch: Diagrams Component Connector End Views M40 Rear Compartment Lid Latch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Diagrams > Page 7331 Trunk / Liftgate Latch: Service and Repair Rear Compartment Lid Latch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Relay > Component Information > Locations Trunk / Liftgate Relay: Locations Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Relay > Component Information > Locations > Page 7335 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair Trunk / Liftgate Striker: Service and Repair Rear Compartment Lid Latch Striker Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations Trunk / Liftgate Switch: Locations Luggage Compartment/Rear of Vehicle Component Views Trunk Components 2 of 2 1 - E7 License Plate Lamp 2 - S58A Rear Compartment Lid Unlatch Switch - Exterior 3 - E7 License Plate Lamp Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Rear Compartment Lid Weatherstrip Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Radiator Grille Emblem/Nameplate Replacement (Chevrolet) Body Emblem: Service and Repair Radiator Grille Emblem/Nameplate Replacement (Chevrolet) Radiator Grille Emblem/Nameplate Replacement (Chevrolet) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Radiator Grille Emblem/Nameplate Replacement (Chevrolet) > Page 7350 Body Emblem: Service and Repair Rear Compartment Lid Emblem/Nameplate Replacement (Bowtie) Rear Compartment Lid Emblem/Nameplate Replacement (Bowtie) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Radiator Grille Emblem/Nameplate Replacement (Chevrolet) > Page 7351 Body Emblem: Service and Repair Rear Compartment Lid Emblem/Nameplate Replacement (Chevrolet) Rear Compartment Lid Emblem/Nameplate Replacement (Chevrolet) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Radiator Grille Emblem/Nameplate Replacement (Chevrolet) > Page 7352 Body Emblem: Service and Repair Rear Compartment Lid Emblem/Nameplate Replacement (Cruze - Left Side) Rear Compartment Lid Emblem/Nameplate Replacement (Cruze - Left Side) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Radiator Grille Emblem/Nameplate Replacement (Chevrolet) > Page 7353 Body Emblem: Service and Repair Radiator Grille Emblem/Nameplate Replacement (Chevrolet) Radiator Grille Emblem/Nameplate Replacement (Chevrolet) Rear Compartment Lid Emblem/Nameplate Replacement (Bowtie) Rear Compartment Lid Emblem/Nameplate Replacement (Bowtie) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Radiator Grille Emblem/Nameplate Replacement (Chevrolet) > Page 7354 Rear Compartment Lid Emblem/Nameplate Replacement (Chevrolet) Rear Compartment Lid Emblem/Nameplate Replacement (Chevrolet) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Radiator Grille Emblem/Nameplate Replacement (Chevrolet) > Page 7355 Rear Compartment Lid Emblem/Nameplate Replacement (Cruze - Left Side) Rear Compartment Lid Emblem/Nameplate Replacement (Cruze - Left Side) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Radiator Grille Emblem/Nameplate Replacement (Chevrolet) > Page 7356 Rear Compartment Lid Emblem/Nameplate Replacement (Cruze - Right Side) Rear Compartment Lid Emblem/Nameplate Replacement (Cruze - Right Side) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Radiator Grille Emblem/Nameplate Replacement (Chevrolet) > Page 7357 Rear Compartment Lid Emblem/Nameplate Replacement (LT or LTZ) Rear Compartment Lid Emblem/Nameplate Replacement (LT or LTZ) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Radiator Grille Emblem/Nameplate Replacement (Chevrolet) > Page 7358 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Windshield Moulding / Trim: > 09-08-110-008C > Oct > 10 > Body - Driver/Passenger Windshield Pillar Moulding Loose Windshield Moulding / Trim: Customer Interest Body - Driver/Passenger Windshield Pillar Moulding Loose TECHNICAL Bulletin No.: 09-08-110-008C Date: October 14, 2010 Subject: Driver and/or Passenger Side Windshield Pillar Garnish Molding Loose, Gap at Top (Install New Fasteners) Models: 2010-2011 Buick LaCrosse 2008-2011 Cadillac CTS, CTS Sport Wagon, DTS 2008-2011 Chevrolet Captiva Sport, Express 2009-2011 Chevrolet Cruze 2008-2011 GMC Savana 2008-2010 Saturn VUE 2009-2011 Daewoo Lacetti Supercede: This bulletin is being revised to update the model information and parts ordering information. Please discard Corporate Bulletin Number 09-08-110-008B (Section 08 - Body and Accessories). Condition Some customers may comment that the driver and/or passenger side windshield garnish molding is loose, has a gap at the top or is falling off. Cause This condition may be caused by the garnish molding retaining clips not fully engaging or not being replaced at a previous service event. The tether clip is a "one time only" use clip. The clip is not designed for multiple cycles of engaging and releasing. Caution Whenever the windshield side garnish molding is removed or replaced, the upper retaining clip and tether must be replaced with a new service retainer clip. Failure to replace the clip may cause the windshield side garnish molding to not fit or function as designed. Do not reuse the old clip - it is a one time only use design. Do not separate the two halves of the service retainer clip. Correction Important Do not replace the windshield garnish molding assembly if it is not affected. The upper tether fastener is available as a service part. Replace only the fastener as instructed in the bulletin procedure. Use the following steps to install the new service garnish molding upper retaining clip. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Windshield Moulding / Trim: > 09-08-110-008C > Oct > 10 > Body - Driver/Passenger Windshield Pillar Moulding Loose > Page 7370 2. Remove the windshield side garnish molding by inserting your fingers between the top of the garnish molding and the headliner. Pull gently to release the clip as shown. 3. With the tether clip open and attached to the body, disengage the clip from the garnish molding. 4. Slide the garnish molding upward to release the molding from the top of the instrument panel. 5. Remove the molding from the vehicle. 6. Depress the tab holding the tether to the metal retainer and remove the tether. 7. Grip the metal retainer with a pair of needle nose pliers as shown. 8. Using a small screwdriver in the hole in the clip, release the inner tab on the metal retainer. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Windshield Moulding / Trim: > 09-08-110-008C > Oct > 10 > Body - Driver/Passenger Windshield Pillar Moulding Loose > Page 7371 9. Twisting the clip with the needle nose pliers will help access the tabs. Use a small screwdriver to release to two outer tabs on the metal retainer and remove the retainer from the vehicle. 10. Insert the new service retaining clip into the garnish molding. Ensure the clip is fully seated into the molding. 11. Insert the lower mounting tabs into the top of the instrument panel. No gap should be present between the molding and the top of the instrument panel. 12. Insert the retaining clip into the body and ensure that the clips are fully seated. Inspect the upper molding area and verify that there is no gap at the headliner. 13. Enable SIR system. Refer to SIR Disabling and Enabling in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Moulding / Trim: > 09-08-110-008C > Oct > 10 > Body - Driver/Passenger Windshield Pillar Moulding Loose Windshield Moulding / Trim: All Technical Service Bulletins Body - Driver/Passenger Windshield Pillar Moulding Loose TECHNICAL Bulletin No.: 09-08-110-008C Date: October 14, 2010 Subject: Driver and/or Passenger Side Windshield Pillar Garnish Molding Loose, Gap at Top (Install New Fasteners) Models: 2010-2011 Buick LaCrosse 2008-2011 Cadillac CTS, CTS Sport Wagon, DTS 2008-2011 Chevrolet Captiva Sport, Express 2009-2011 Chevrolet Cruze 2008-2011 GMC Savana 2008-2010 Saturn VUE 2009-2011 Daewoo Lacetti Supercede: This bulletin is being revised to update the model information and parts ordering information. Please discard Corporate Bulletin Number 09-08-110-008B (Section 08 - Body and Accessories). Condition Some customers may comment that the driver and/or passenger side windshield garnish molding is loose, has a gap at the top or is falling off. Cause This condition may be caused by the garnish molding retaining clips not fully engaging or not being replaced at a previous service event. The tether clip is a "one time only" use clip. The clip is not designed for multiple cycles of engaging and releasing. Caution Whenever the windshield side garnish molding is removed or replaced, the upper retaining clip and tether must be replaced with a new service retainer clip. Failure to replace the clip may cause the windshield side garnish molding to not fit or function as designed. Do not reuse the old clip - it is a one time only use design. Do not separate the two halves of the service retainer clip. Correction Important Do not replace the windshield garnish molding assembly if it is not affected. The upper tether fastener is available as a service part. Replace only the fastener as instructed in the bulletin procedure. Use the following steps to install the new service garnish molding upper retaining clip. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Moulding / Trim: > 09-08-110-008C > Oct > 10 > Body - Driver/Passenger Windshield Pillar Moulding Loose > Page 7377 2. Remove the windshield side garnish molding by inserting your fingers between the top of the garnish molding and the headliner. Pull gently to release the clip as shown. 3. With the tether clip open and attached to the body, disengage the clip from the garnish molding. 4. Slide the garnish molding upward to release the molding from the top of the instrument panel. 5. Remove the molding from the vehicle. 6. Depress the tab holding the tether to the metal retainer and remove the tether. 7. Grip the metal retainer with a pair of needle nose pliers as shown. 8. Using a small screwdriver in the hole in the clip, release the inner tab on the metal retainer. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Moulding / Trim: > 09-08-110-008C > Oct > 10 > Body - Driver/Passenger Windshield Pillar Moulding Loose > Page 7378 9. Twisting the clip with the needle nose pliers will help access the tabs. Use a small screwdriver to release to two outer tabs on the metal retainer and remove the retainer from the vehicle. 10. Insert the new service retaining clip into the garnish molding. Ensure the clip is fully seated into the molding. 11. Insert the lower mounting tabs into the top of the instrument panel. No gap should be present between the molding and the top of the instrument panel. 12. Insert the retaining clip into the body and ensure that the clips are fully seated. Inspect the upper molding area and verify that there is no gap at the headliner. 13. Enable SIR system. Refer to SIR Disabling and Enabling in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair Front Wheelhouse Liner Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair Rear Fender Liner: Service and Repair Rear Wheelhouse Panel Liner Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair Skid Plate: Service and Repair Engine Shield Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair Front Subframe: Service and Repair Drivetrain and Front Suspension Frame Replacement Removal Procedure 1. Support the radiator and condenser from above using the condenser tabs on each side. 2. Remove the lower steering intermediate shaft bolt (1). 3. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle . 4. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation . 5. Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement . 6. Remove the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement (See: Splash Guard/Service and Repair/Front Compartment Splash Shield Replacement). 7. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Skid Plate/Service and Repair). 8. Remove the front compartment insulator, if equipped. Refer to Front Compartment Insulator Replacement (See: Splash Guard/Service and Repair/Front Compartment Insulator Replacement). 9. Remove the wheel speed sensor wiring harness (2) from the frame on both sides. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Page 7396 Remove the wiring harness retainers (3) from the frame and the lower control arm. 10. Remove the radiator wiring harness (1) from the frame. Remove the wiring harness retainers (4) from the frame. 11. Remove the lower ball joints from the steering knuckles. Refer to Lower Control Arm Replacement . 12. Remove the stabilizer link nut (1) from the strut. 13. Remove the outer tie rods and tie rod nuts from the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement . 14. Remove the front (1) and the rear (2) transmission mount bracket bolts. 15. Install the engine support fixture. For the 1.4L engine, refer to Engine Support Fixture . For the 1.8L engine, refer to Engine Support Fixture . 16. Turn the front wheels to the straight forward position and secure the steering wheel from moving. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Page 7397 17. Carefully disconnect 2 wiring harness plugs (3) from the steering gear with a suitable tool. Use the following procedure to disconnect the 2 wiring harness plugs: 1. Insert a small flat bladed tool into the pocket of the connector retention feature. 2. Gently move the retention feature back and pull on the connector to disconnect the connector. 18. Using a suitable engine support table or equivalent, lower the vehicle until the drivetrain and front suspension frame contacts the engine support table. 19. Secure the power steering gear to the vehicle. 20. Remove the frame front bolts (1). 21. Remove the frame rear bolts (2). 22. Remove the frame reinforcements (3). 23. Remove the frame (4) from the vehicle. 24. Remove the following components if replacing the frame: * The lower control arms-Refer to Lower Control Arm Replacement . * The stabilizer shaft-Refer to Stabilizer Shaft Replacement . * The radiator support brackets. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Page 7398 * The steering gear-Refer to Steering Gear Replacement . Installation Procedure 1. Install the following components on the drivetrain and front suspension frame if removed: * The radiator support brackets. * The stabilizer shaft-Refer to Stabilizer Shaft Replacement . * The lower control arms-Refer to Lower Control Arm Replacement . * The steering gear-Refer to Steering Gear Replacement . 2. Install the frame (4) into the vehicle. 3. Install the frame reinforcements (3). Caution: Refer to Fastener Caution . 4. Install the frame rear bolts (2) and tighten to 160 Nm (118 lb ft). 5. Install the frame front bolts (1) and tighten to 160 Nm (118 lb ft). 6. Remove the support for the power steering gear. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Page 7399 7. Install and tighten 2 wiring harness bracket bolts (4) to 9 Nm (80 lb in). 8. Tighten wiring harness retainer (1) to steering gear. 9. Connect 2 wiring harness plugs (3). 10. Install the front bumper energy absorber bracket bolt. 11. Install the front transmission mount bolt (1) and tighten to 100 Nm (74 lb ft). 12. Install the rear transmission mount bracket bolt (2) and tighten to 100 Nm (74 lb ft). 13. Install the outer tie rods and tie rod nuts to the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement . Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Page 7400 14. Install the steering linkage tie rod. Tighten the steering linkage tie rod nut to 35 Nm (26 lb ft). 15. Install the lower ball joints to the steering knuckles. Refer to Lower Control Arm Replacement . 16. Install the wheel speed sensor wiring harness (2) to the frame on both sides. Install the wiring harness retainers (3) to the frame and the lower control arm. 17. Install the radiator wiring harness (1) to the frame. Install the wiring harness retainers (4) to the frame. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Page 7401 18. Install the lower steering intermediate shaft (1) bolt and tighten to 34 Nm (25 lb ft). 19. Remove the support of the radiator and condenser. 20. Lower the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle . 21. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation . 22. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement . 23. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Skid Plate/Service and Repair). 24. Install the engine splash shields. Refer to Front Compartment Splash Shield Replacement (See: Splash Guard/Service and Repair/Front Compartment Splash Shield Replacement). 25. Install the front compartment insulator, if equipped. Refer to Front Compartment Insulator Replacement (See: Splash Guard/Service and Repair/Front Compartment Insulator Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Service and Repair Front Subframe Mount: Service and Repair Drivetrain and Front Suspension Frame Front Insulator Replacement Special Tools * CH-906-14 - Adapter * CH-906-42 - Adapter * CH-50342 - Threaded Rod For equivalent regional tools. Refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Remove the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement (See: Front Subframe/Service and Repair). 2. Mark installation position of insulator (2) at frame (1). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Service and Repair > Page 7405 Note: Drilling holes into the insulator rubber to ease removal of the core. 3. Cut out frame insulator core (1) from frame insulator (2). 4. Remove frame insulator core (1) from outer frame insulator (2). 5. Remove the frame insulator (3) from drivetrain and front suspension frame (1) using a chisel (2) or equivalent. Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Service and Repair > Page 7406 1. Install the following components on the drivetrain and front suspension frame: * CH-906-14 - Adapter. * CH-906-42 - Adapter. * CH-50342 - Threaded Rod. Note: Check marking of frame insulator. * Align the insulator tab with the alignment marks (1) on the frame. 2. Carefully install the frame insulator in to the front suspension frame. 3. Install the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement (See: Front Subframe/Service and Repair). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Front Bumper Lower Fascia Center Grille Replacement Grille: Service and Repair Front Bumper Lower Fascia Center Grille Replacement Front Bumper Lower Fascia Center Grille Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Front Bumper Lower Fascia Center Grille Replacement > Page 7411 Grille: Service and Repair Radiator Lower Grille Replacement Radiator Lower Grille Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Front Bumper Lower Fascia Center Grille Replacement > Page 7412 Grille: Service and Repair Front Bumper Lower Fascia Grille Replacement Front Bumper Lower Fascia Grille Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Front Bumper Lower Fascia Center Grille Replacement > Page 7413 Grille: Service and Repair Radiator Upper Grille Replacement Radiator Upper Grille Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats Carpet: Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 7419 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures Carpet: Procedures Floor Carpet Drying If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the components: * For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire assembly. * For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only. While the carpet is out of the vehicle, dry the carpet using the method described below. * For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding, dry the carpet using the method described below. * For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method described below. Drying Method 1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess moisture. 2. Blot the face of the carpet with a towel in order to absorb as much moisture as possible. 3. Point a fan at the affected area and air dry the carpet. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 7422 Carpet: Removal and Replacement Front Floor Panel Carpet Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Armrest Replacement Console: Service and Repair Front Floor Console Armrest Replacement Front Floor Console Armrest Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Armrest Replacement > Page 7427 Console: Service and Repair Front Floor Console Replacement Front Floor Console Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Armrest Replacement > Page 7428 Console: Service and Repair Front Floor Console Rear Cover Replacement Front Floor Console Rear Cover Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Armrest Replacement > Page 7429 Console: Service and Repair Roof Console Replacement Roof Console Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Armrest Replacement > Page 7430 Console: Service and Repair Front Floor Console Storage Tray Replacement Front Floor Console Storage Tray Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Restraint Systems/Air Bag Systems/Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 7435 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Restraint Systems/Air Bag Systems/Diagrams/Electrical Diagrams ) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Compartment Replacement Glove Compartment: Service and Repair Instrument Panel Compartment Replacement Instrument Panel Compartment Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Compartment Replacement > Page 7440 Glove Compartment: Service and Repair Instrument Panel Upper Compartment Replacement Instrument Panel Upper Compartment Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (With Sunroof) Headliner: Service and Repair Headlining Trim Panel Replacement (With Sunroof) Headlining Trim Panel Replacement (with Sunroof) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (With Sunroof) > Page 7445 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (With Sunroof) > Page 7446 Headliner: Service and Repair Headlining Trim Panel Replacement (Without Sunroof) Headlining Trim Panel Replacement (without Sunroof) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (With Sunroof) > Page 7447 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair Passenger Assist Handle: Service and Repair Assist Handle Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Front Side Door Sill Trim Plate Replacement Scuff Plate: Service and Repair Front Side Door Sill Trim Plate Replacement Front Side Door Sill Trim Plate Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Front Side Door Sill Trim Plate Replacement > Page 7455 Scuff Plate: Service and Repair Rear Side Door Sill Trim Plate Replacement Rear Side Door Sill Trim Plate Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Sunshade Replacement Sun Visor: Service and Repair Sunshade Replacement Sunshade Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Sunshade Replacement > Page 7460 Sun Visor: Service and Repair Sunshade Support Replacement Sunshade Support Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Inside Rearview Mirror Mount Plate Cover Replacement Trim Panel: Service and Repair Inside Rearview Mirror Mount Plate Cover Replacement Inside Rearview Mirror Mount Plate Cover Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Inside Rearview Mirror Mount Plate Cover Replacement > Page 7465 Trim Panel: Service and Repair Quarter Window Garnish Molding Replacement Quarter Window Garnish Molding Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Inside Rearview Mirror Mount Plate Cover Replacement > Page 7466 Trim Panel: Service and Repair Rear Side Door Window Garnish Molding Replacement Rear Side Door Window Garnish Molding Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Inside Rearview Mirror Mount Plate Cover Replacement > Page 7467 Trim Panel: Service and Repair Front Side Door Window Garnish Molding Replacement Front Side Door Window Garnish Molding Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Inside Rearview Mirror Mount Plate Cover Replacement > Page 7468 Trim Panel: Service and Repair Inside Rearview Mirror Mount Plate Cover Replacement Inside Rearview Mirror Mount Plate Cover Replacement Quarter Window Garnish Molding Replacement Quarter Window Garnish Molding Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Inside Rearview Mirror Mount Plate Cover Replacement > Page 7469 Rear Side Door Window Garnish Molding Replacement Rear Side Door Window Garnish Molding Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Inside Rearview Mirror Mount Plate Cover Replacement > Page 7470 Front Side Door Window Garnish Molding Replacement Front Side Door Window Garnish Molding Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Inside Rearview Mirror Mount Plate Cover Replacement > Page 7471 Body Side Trim Panel Replacement - Left Side Body Side Trim Panel Replacement - Left Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Inside Rearview Mirror Mount Plate Cover Replacement > Page 7472 Body Side Trim Panel Replacement - Right Side Body Side Trim Panel Replacement - Right Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Inside Rearview Mirror Mount Plate Cover Replacement > Page 7473 Center Pillar Lower Garnish Molding Replacement Center Pillar Lower Garnish Molding Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Inside Rearview Mirror Mount Plate Cover Replacement > Page 7474 Center Pillar Upper Garnish Molding Replacement Center Pillar Upper Garnish Molding Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Inside Rearview Mirror Mount Plate Cover Replacement > Page 7475 Rear Compartment Floor Panel Trim Replacement Rear Compartment Floor Panel Trim Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Inside Rearview Mirror Mount Plate Cover Replacement > Page 7476 Rear Compartment Lid Inner Panel Trim Replacement Rear Compartment Lid Inner Panel Trim Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Inside Rearview Mirror Mount Plate Cover Replacement > Page 7477 Rear Compartment Side Trim Replacement - Left Side Rear Compartment Side Trim Replacement - Left Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Inside Rearview Mirror Mount Plate Cover Replacement > Page 7478 Rear Compartment Side Trim Replacement - Right Side Rear Compartment Side Trim Replacement - Right Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Inside Rearview Mirror Mount Plate Cover Replacement > Page 7479 Rear Compartment Sill Trim Plate Replacement Rear Compartment Sill Trim Plate Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Inside Rearview Mirror Mount Plate Cover Replacement > Page 7480 Rear Window Panel Trim Replacement Rear Window Panel Trim Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Inside Rearview Mirror Mount Plate Cover Replacement > Page 7481 Windshield Garnish Molding Replacement Windshield Garnish Molding Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Inside Rearview Mirror Mount Plate Cover Replacement > Page 7482 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair Door Lock Cylinder: Service and Repair Front Side Door Lock Cylinder Rod Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Knob > Component Information > Service and Repair Door Lock Knob: Service and Repair Front or Rear Side Door Locking Rod Knob Trim Cover Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Interior/Locks - Key Cutting Procedure Key: Technical Service Bulletins Interior/Locks - Key Cutting Procedure INFORMATION Bulletin No.: 09-00-89-029F Date: January 05, 2011 Subject: Key Cutting Procedure for Obtaining Replacement Key Models: 2010-2011 Buick LaCrosse 2011 Buick Regal 2010-2011 Chevrolet Camaro, Equinox 2011 Chevrolet Cruze, Volt 2010-2011 GMC Terrain 2008-2009 Pontiac G8 Attention: This bulletin applies to the United States and Canada only. Export dealers are to contact their local Technical Assistance Center (TAC) for further information. Supercede: This bulletin is being revised to add the Chevrolet Volt. Please discard Corporate Bulletin Number 09-00-89-029E (Section 00 - General Information). Due to the uniqueness of the ignition/door lock key, special equipment is required to cut a key. If you do not have the required equipment, you may order a cut/coded key through GM CC&A.; To obtain a replacement key, the following procedure is suggested: 1. Obtain the vehicle key code. U.S. Dealers: Access the "Key Code Look Up" application through GM GlobalConnect under the Parts Workbench. Canadian Dealers: Access the "KeyCode Look-Up" feature within the OEConnection D2DLink application. 2. Submit a part order through the GM CC&A; Parts System for a key blank. Be sure to include the key code in the "note" field of the order. 3. DO NOT ORDER AN UNCODED KEY AS YOU WILL RECEIVE A BLANK KEY THAT WILL REQUIRE CODING ON THE SPECIAL EQUIPMENT LISTED BELOW. Note The key code is five digits. Some vehicle records do not have the first digit displayed (i.e., vehicle records show the key code as "1234"). When ordering a cut/coded key, refer to the key code table. Important The order will be shipped the same day if received by 12:00 p.m. (noon) EST, or within 24 hours, Monday through Friday via FedEx (Canadian dealers should place their orders for these parts using a CSO order type only. Do not order using the CSO3 order type). Important The remote control transmitter and the key shank are not serviced separately. Important Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Interior/Locks - Key Cutting Procedure > Page 7495 If a key is received with an incorrect cut contact the SPAC department for assistance. Tip The new key and transmitter will need to be programmed to the vehicle. Refer to Key and Transmitter Programming in SI for details. Parts Information For part numbers and usage, refer to Key in Group 02.187 of the appropriate parts catalog. Important As an alternate to Step 2, the following equipment can be purchased through 1-800-GM-TOOLS or by visiting www.GMDEsolutions.com (U.S.) or www.des-canada.ca (Canada). General Motors highly recommends the use of the following key machines. General Motors has identified superior equipment through testing and evaluation. General Motors believes these sources and their equipment to be reliable. There may be additional manufacturers of such equipment. General Motors does not endorse, indicate any preference for or assume any responsibility for the equipment from these firms or for any such items which may be available for other sources. Equipment Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Antenna - Keyless Entry > Component Information > Service and Repair Antenna - Keyless Entry: Service and Repair Ignition Lock Key Transmitter Antenna Replacement - Floor Console Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Passenger Compartment/Roof Component Views Roof/Headliner Components 1 - B160 Windshield Temperature and Inside Moisture Sensor 2 - K84 Remote Function Receiver Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Diagrams Keyless Entry Receiver: Diagrams Component Connector End Views K77 Remote Control Door Lock Receiver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Diagrams > Page 7506 Keyless Entry Receiver: Service and Repair Remote Control Door Lock Receiver Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Transmitter: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7511 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7512 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7513 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7514 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7515 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7516 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7517 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7518 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7519 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7520 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7521 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7522 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7523 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7524 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7525 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7526 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7527 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7528 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7529 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7530 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7531 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7532 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7533 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7534 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7535 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7536 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7537 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7538 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7539 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7540 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7541 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7542 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7543 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7544 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7545 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7546 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7547 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7548 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7549 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7550 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7551 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7552 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7553 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7554 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7555 Keyless Entry Transmitter: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7556 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7557 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7558 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools EL-35616-200 - Test Light - Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A Digital Multimeter (DMM) should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The EL-35616-200 - kit is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7559 Testing for a Short to Voltage Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J-25070 - Heat Gun For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, to move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to the Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J-25070 - heat gun. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7560 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. In addition, circuit cooling spray can be used to cool down a component or circuit. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7561 For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Special Tools Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7562 EL-35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7563 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Using Snapshots in Global Diagnostic System (GDS) Overview Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7564 A snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. To record a snapshot in GDS, select, Record Snapshot, from the options at the top right portion of any of the various pages that allow snapshots to be taken (e.g. Data Display, Control Functions, etc.). When you are finished recording, select, Stop Snapshot recording. The snapshot will now be available for replay. Snapshot Replay The Snapshot Replay function allows reviews of previously recorded vehicle snapshot data. This information can be used in analysis of vehicle problems and detection of trigger error conditions. The graph function can be used to compare parameters to see if a component is functioning properly. Recorded snapshots can be selected for viewing by the following three methods: * Selecting a snapshot file from the Vehicle Home Page and clicking on the Review selection. * Double clicking on the selected snapshot from the Vehicle Home Page. * Entering the Tools selection from the Menu selection and selecting Snapshot replay. Next, open the Snapshot Manager. Double click on the snapshot file you wish to view or click on the Load Snapshot selection and select a snapshot file. Regardless of selection method, a File Loaded pop-up window will be displayed from the Snapshot Replay screen. Select OK from the pop-up window. Snapshot Play Functions There are several snapshot play functions that are used to replay recorded snapshots * The Play function is used to play the snapshot forward by clicking on this selection. A marker will move across the screen when this selection is used. All selections in this area turn grey when they are active. * The Pause function is used to pause play of the snapshot. When this selection is clicked a second time the snapshot will start playing where it left off. * The Stop function is used to stop playing the snapshot. The snapshot will start from the beginning, if Play is selected after using the Stop function. Time Control Time control is used to control the snapshot replay. This function allows selection of a specific time frame, display of different views, and control of display speed. The following functions can be selected directly under Time Control. * The Bookmark selection allows you to add a specific comment in the current display and return to this point in the future. When this option is selected, a pop-up window is displayed. Enter a bookmark name and select OK. * The Note Pad can be selected to add comments to the snapshot replay file at the current point of time. When this option is selected, a pop-up window is displayed. Enter a comment for the snapshot file and select OK. * The Load Snapshot (blue folder) opens a snapshot file and makes it ready for further analysis. This function is also available by clicking on an available snapshot file from the Snapshot Manager. * The Down Arrow displays all Time Control options when selected. Individual options can also be selected by clicking on the item you want. * The Snapshot Display Speed can be controlled by selecting this option. Slow speeds of 1/8X, 1/4X, and 1/2X can be selected. The real time speed can also be selected at 1. Faster speeds of 2X, 4X, and 8X can also be obtained by using this selection. View Selections Each View Selection provides a different way of displaying vehicle data for analysis. The following functions can be selected under Available Views: Note: The parameter name will be shown in the original language used for capture if no translation is available for the name. * Parameter List View - Displays incoming information from the snapshot file. The current value of the parameters is displayed on the screen. * Log View - Contains all the information from the snapshot file. All parameter values are listed in the order they were recorded. Specific parameters can be added or removed from a watchlist by clicking on the appropriate item. * State View - Shows the values of all parameters in a specific time frame. These values can be used for comparison with the trigger view. * Trigger View - Displays all system and user defined triggers. This function can be used when there is a combination of factors involved in a diagnostic problem. When a Trigger condition is met a caution triangle will be displayed on the screen. Triggers: * Load Triggers - Allows you to load a file containing trigger definitions. * Save Triggers - Allows you to save the trigger to your computer's hard drive. * Remove Trigger - Allows you to remove the current trigger. It will no longer be present. * Edit Trigger - Displays a pop-up window where you can modify the limits and parameters contained within a trigger. * Adds Trigger - Displays a pop-up window to configure a trigger. * DTC View - After the Play function is selected and this option is selected this function opens the list of recorded DTCs. * Line Graph View - Displays data that can be visualized against the time-axis. From this view, specific parameters can be selected for graphing by Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7565 checking the box under Selected. At the bottom of the graph there are four functions Zoom In (increase size), Zoom Out (decrease size), Bookmarks, and Pause Scrolling. Each of these functions can be accessed by clicking on them. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools EL-39200 - Digital Multimeter For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the EL-39200 - digital multimeter (DMM). This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. Note: The DMM must be used in order to perform the following procedure since the DMM can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7566 Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the DMM to the circuit. 2. Set the DMM to the V (AC) or V (DC) position. 3. Select the voltage range feature of the DMM in order to select the desired voltage range. Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 4. Select the MIN MAX function of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button until the MAX value is displayed and note the value. 8. Press the MIN MAX button until the MIN value is displayed and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools EL-35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7567 To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the EL-35616 - kit when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center. Use EL-35616 - kit to test for proper terminal contact. Failure to use EL-35616 - kit can result in improper diagnosis of the bussed electrical center. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal/terminated lead, verify that the retention force is significantly different between a known good terminal and the suspect terminal. Replace the female terminal in question. Flat Wire Connectors There are no serviceable parts for flat wire connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter into the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7568 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures - In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference or other types of electrical noise. Inspect for the following conditions: * A mis-routed harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc.-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc.-These accessories may create interference in other circuits while operating and the interference would disappear when the accessory is not operating. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7569 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, current, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 Mohm input impedance 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Current 1. Test a DC current range of 0.1 µA-10 A. 2. Test an AC current range of 0.1 µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 Mohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 Hz-199 k Hz Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7570 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 25 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the engine control module (ECM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the EL-39200. The DMM instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Special Tools EL 35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools EL 35616-20F - Fused Jumper Wire For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: A fused jumper may not protect solid state components from being damaged. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7571 The EL 35616-20F - Fused Jumper Wire includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool * J-38125-216 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7572 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7573 3. Slide the lever lock forward while pressing down on the lever lock release tab. 4. View showing depressing of the lever lock release tab. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7574 5. View of connector in released position. 6. Disconnect the connector from the component. 7. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 8. Release the rear lower half of the wiredress cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7575 9. Release the tabs that are holding the wiredress cover to the connector body. 10. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J-38125-216 can also be used to remove the nose piece. 11. Use the J-38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7576 12. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 13. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 14. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-561 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7577 4. Insert the J-38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-213 - Terminal Release Tool * J-38125-556 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7578 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7579 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7580 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J-38125-213 or the J-38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. 10. Reconnect the connector bodies. Bosch Connectors (0.64) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7581 Bosch Connectors (0.64) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7582 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7583 11. Insert the J-38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 13. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 14. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7584 Bosch Connectors (2.8 JPT) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-557 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J-38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7585 * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT) )Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock))FCI Connectors (SIR) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI (SIR)) * FEP Connectors (Steering Gear) (See: General Electrical Diagnostic Procedures/Connector Repairs/FEP Connectors (Steering Gear)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) Connector Anatomy Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7586 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7587 * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7588 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7589 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7590 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7591 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools EL-38125-580 - Terminal Release Tool Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7592 Terminal Removal Procedure Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull to Seat) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7593 Delphi Connectors (Pull To Seat) Special Tools EL-38125-580 - Terminal Release Tool Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Review the connector end view to determine the proper test probe and release tool. 5. Insert the release tool into the front of the connector body. 6. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 3. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-21 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7594 Terminal Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7595 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7596 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wire dress cover and pull the lever over and past the locks. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7597 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7598 Note: Be careful not to angle or rock the J-38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J-38125-21 tool into the round canal between the terminals cavities at the front of the connector. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7599 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7600 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7601 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7602 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J-38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7603 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-10A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J-38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7604 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (12-Way) Delphi Connectors (12-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7605 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7606 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7607 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J-38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7608 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (Steering Gear) Delphi Connectors (Steering Gear) Removal Procedure 1. Use a small flat-bladed tool to release the locking tab on the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7609 2. Push down the locking tab to release the connector. The small flat-bladed tool may need to be pushed down and angled back slightly to depress the locking tab. Pull on the connector body while releasing the locking tab to disconnect the connector. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-556 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7610 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7611 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. 7. For the larger terminals insert the J-38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J-38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7612 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 9. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 10. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. FCI (SIR) FCI Connectors (SIR) Removal Procedure Note: The orange connector position assurance (CPA) must be released first to disconnect or to connect the connector. 1. Lift the orange CPA vertically (avoid lifting on an angle to the connector) approximately 4 mm to release the connector. Use a small flat-bladed Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7613 tool to help release the orange CPA. The orange CPA can also be released manually without any tools. 2. Grab the connector on both sides and lift the connector vertically to disconnect the connector. Installation Procedure 1. Lift the orange CPA vertically approximately 4 mm before installing the connector. Use a small flat-bladed tool to help release the orange CPA. The orange CPA can also be released manually without any tools. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7614 2. Line up the connector key tabs with the initiator key slots. Grab the connector on both sides and push the connector down into the initiator connector sub assembly until fully seated. 3. After the connector is fully seated, push down the orange CPA with your thumb. Push down until the orange CPA is touching the yellow cover on the connector. FEP Connectors (Steering Gear) FEP Connectors (Steering Gear) Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7615 1. Use a small flat-bladed tool to release the locking tab on the connector. 2. Push down the locking tab to release the connector. The small flat-bladed tool may need to be pushed down and angled back slightly to depress the locking tab. Pull on the connector body while releasing the locking tab to disconnect the connector. JST Connectors JST Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7616 The JST connector family consists of seven unique connector housings differentiated by color and keying. This connector family is designed to use both 0.64 and 2.8 sized terminals. 1. While depressing the lock, remove the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7617 2. Unlock the terminal position assurance (TPA): * Position connector as shown (above) and locate TPA staging cavities. * Using connector terminal release tool J-38125-553 (1) lift the TPA into the staged position (figure 1). Perform this step on both sides of the TPA. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7618 * You will feel the TPA click into place when fully extended into the staged position. The figure above shows the TPA (1) in the staged position. 3. Release the terminal from the connector: * Position the connector as shown (above) and locate the terminal release entry canal (1) of the suspect terminal. * Insert the connector terminal release tool J-38125-553 into the entry canal with the angled side of the tool facing the connector wall containing cavity 4 (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7619 * The cavity on the left (1) is a 2.8 mm cavity and the cavity on the right (2) is a 0.64 mm cavity. * Place the tip of the connector terminal release tool onto the connector lance (3) and deflect the lance to the right (5) to release the lock. Hold this released position. * Holding the lance in the released position, slightly pull on the suspect terminal to remove it from the connector housing. The side TPA (4) is a secondary lock. 4. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 5. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-24 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7620 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7621 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7622 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7623 8. Use the J-38125-24 or the J-38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-28 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7624 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7625 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J-38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7626 locked in place by gently pulling on the wire. 3. Locate the TPA. 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7627 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-213 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7628 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7629 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7630 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J-38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7631 Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7632 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J-38125-12A - tool into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7633 7. Pressing the J-38125-12A - tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool * J-38125-13A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-bladed tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7634 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-bladed tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J-38125-13A - tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J-38125-12A - tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7635 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7636 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7637 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7638 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7639 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7640 6. Use the J-38125-12A tool to release the terminals by pressing on the tang. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool * J-38125-212 - Terminal Release Tool * J-38125-216 - Terminal Release Tool * J-38125-221 - Terminal Release Tool * J-38125-560 - Terminal Release Tool * J-38125-566 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7641 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7642 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7643 Note: During assembly the terminal position assurance (TPA) will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J-38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7644 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7645 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7646 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J-38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7647 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7648 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7649 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7650 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7651 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. 22. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 23. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool * J-38125-212 - Terminal Release Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7652 * J-38125-556 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7653 Note: Terminal position assurance (TPA) is keyed and can only be inserted in one direction. 3. Using terminal release tool J-38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7654 5. Using terminal release tool J-38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7655 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7656 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7657 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7658 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7659 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7660 * J-38125-552 - Terminal Release Tool * J-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7661 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7662 5. Once the nose piece retainers are relaxed, use the J-38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7663 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7664 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7665 2. Insert the J-38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7666 5. Insert the J-38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-24 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7667 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7668 5. While pushing the terminal forward, insert the J-38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7669 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J-38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7670 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-215 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7671 1. While depressing the lock, pull the two connector halves apart. Note: The terminal position assurance (TPA) is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the TPA towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7672 4. View of the female half of the connector with male terminals. 5. Use the J-38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. 6. View of the female half of the connector with male terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7673 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 9. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 10. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Repairing Connector Terminals (Terminated Lead Repair) Repairing Connector Terminals (Terminated Lead Repair) Special Tools * EL-38125-10 - Splice Sleeve Crimp Tool * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs procedures. For high temperature wiring repairs, refer to High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs). Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to in Splicing Copper Wire Using Splice Sleeves to identify the correct DuraSeal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Repairing Connector Terminals (Terminal Repair) Repairing Connector Terminals (Terminal Repair) Special Tools * J-38125 - Terminal Repair Kit * J-38125-6 - Crimp Tool * J-38125-7 - Crimp Tool * J-38125-8 - Crimp Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7674 * J-38125-64 - Crimp Tool * J-38125-101 - Crimp Tool * J-38125-641 - Crimp Tool * J-38125-642 - Crimp Tool * J-38125-643 - Crimp Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Use the following repair procedures to repair each type of terminal: * For push to seat terminals, refer to Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)). * For pull to seat terminals, refer to Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)). Note: The first step for all terminal repairs is to find the connector end view in SI. Cable Seal Terminals 1. Cut off the terminal between the core and the insulation crimp to minimize any wire loss. 2. Remove the old seal. 3. Apply the correct cable seal, per the wire gauge size, from the kit. Slide the seal back along the wire to enable removal of the insulation. 4. To minimize wire loss, remove only the insulation required. 5. Using the connector end view, determine the correct crimp tool and crimp jaw. 6. Align the seal with the end of the cable insulation. 7. Position the stripped wire and seal in the terminal. 8. Hand Crimp the core wings first. 9. Hand Crimp the insulation wings around the seal and the cable. 10. Solder all of the hand crimp terminals except the Micro-Pack 100 and 0.64 sizes. Unsealed Terminals 1. Cut off the terminal between the core and the insulation crimp to minimize any wire loss. 2. To minimize wire loss, remove only the insulation required. 3. Position the stripped wire in the terminal. 4. Hand Crimp the core wings first. 5. Hand Crimp the insulation wings around the cable. 6. Solder all of the hand crimp terminals except the Micro-Pack 100 and 0.64 sizes. Micro-Pack 100W Size Terminal The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7675 the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Micro 0.64 Size Terminal The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J-38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J-38125-64 crimping tool is also designed to crimp Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7676 both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7677 7. Place the terminal into the appropriate cavity and assemble the connector. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7678 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch Special Tool * DuraSeal splice sleeves * A wire stripping tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7679 For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A terminated lead can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs in the service information connector end views or the vehicle schematics in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and EL-38125-10 - tool. For wiring repair, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. High Temperature Wiring Repairs High Temperature Wiring Repairs Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7680 Note: All wiring repairs need to be 200 mm from the heat zone. Areas of consideration would be any area located near the exhaust manifolds, catalytic converter, exhaust pipes, and turbocharged engines. Items Required * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * Terminated leads or pigtails * The correct tools to remove the terminals from the connectors Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing. * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Note: High temperature areas would be areas located near exhaust manifolds, catalytic converters, exhaust pipes, and turbocharged engines. Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7681 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. Terminated leads can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs in the service information connector end views or the vehicle schematics in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7682 the DuraSeal splice sleeves and EL-38125-10 - tool. For wiring repair, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). For connector position assurance (CPA), refer to Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks). For terminal position assurance (TPA), refer to Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks). Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except Tefzel and coaxial. Use DuraSeal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert to regional wiring gauge size. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. For high temperature wiring, slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7683 tubing will not interfere with the splice procedure. 5. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 6. Use the splice sleeve crimp tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 7. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 8. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 9. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4, 6 and 15 for the opposite end of the splice. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7684 10. Using the heat torch, apply heat to the crimped area of the barrel. 11. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. High Temperature Wiring Repairs Use the following procedures to perform high temperature wiring repairs: 1. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 2. Using the heat torch, apply heat to the high temperature heat shrink tubing. 3. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 4. Replace any reflective tape and clips that may have been removed during the repair. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7685 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7686 * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7687 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7688 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7689 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. Note: Some terminals have a lever that must be disengaged before the terminal can be released. * Insert the terminal release tool into the cavity. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7690 Special Tools * EL-38125-10 - Splice Sleeve Crimp Tool * EL-38125-580 - Terminal Release Tool Kit * J-38125-5 - Ultra Torch * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7691 (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 7692 Keyless Entry Transmitter: Electrical Diagrams Remote Function Schematics Keyless Entry Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Page 7693 Keyless Entry Transmitter: Tools and Equipment Special Tools Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations Instrument Panel/Center Console Component Views Center of the I/P Components 1 - P16 Instrument Cluster 2 - P17 Info Display Module 3 - S26 Hazard Lamps Switch 4 - A26 HVAC Control 5 - S13D Door Lock Switch - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 7698 Power Door Lock Switch: Diagrams Component Connector End Views S13D Door Lock Switch - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 7699 Power Door Lock Switch: Service and Repair Door Lock Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Door Component Views Driver Door Components 1 - S79D Window Switch - Driver 2 - S52 Outside Rearview Mirror Switch 3 - A9A Outside Rearview Mirror - Driver 4 - P19G Speaker - Left Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7704 Power Mirror Switch: Diagrams Component Connector End Views S52 Outside Rearview Mirror Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7705 Power Mirror Switch: Service and Repair Outside Remote Control Rearview Mirror Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Brake Fluid Effects on Paint and Electrical Components Caution Paint: Service Precautions Brake Fluid Effects on Paint and Electrical Components Caution Brake Fluid Effects on Paint and Electrical Components Caution Caution: Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables. Brake fluid will damage painted surfaces and cause corrosion to electrical components. If any brake fluid comes in contact with painted surfaces, immediately flush the area with water. If any brake fluid comes in contact with electrical connections, wiring, or cables, use a clean shop cloth to wipe away the fluid. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Brake Fluid Effects on Paint and Electrical Components Caution > Page 7711 Paint: Service Precautions Clearcoat/Ultraviolet Screeners Caution Clearcoat/Ultraviolet Screeners Caution Caution: Removing more than 0.5 mils of the clearcoat can result in early paint failure. The clearcoat contains ultraviolet screeners. Do not finesse sand more than what is required to remove the defect. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Page 7712 Paint: Application and ID Paint Identification Warning Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Note: Always refer to the GM Approved Refinish Materials book. This book identifies the paint systems you may use. The latest revision of the GM Approved Refinish Materials booklet is located on the Goodwrench website at www.gmgoodwrench.com. Use the service parts identification label to identify the type of paint technology, paint codes, trim level, and any special order paint colors on the vehicle. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label . Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair > Radiator Grille Reinforcement Support Replacement Radiator Support: Service and Repair Radiator Grille Reinforcement Support Replacement Radiator Grille Reinforcement Support Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair > Radiator Grille Reinforcement Support Replacement > Page 7717 Radiator Support: Service and Repair Front End Upper Tie Bar Replacement Front End Upper Tie Bar Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Passenger Compartment/Roof Component Views Roof/Headliner Components 1 - B160 Windshield Temperature and Inside Moisture Sensor 2 - K84 Remote Function Receiver Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams Seat Heater Control Module: Diagrams Component Connector End Views K29 Seat Heating Control Module X2 (KA1) K29 Seat Heating Control Module X3 (KA1) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 7725 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 7726 Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations Sunroof / Moonroof Module: Locations Passenger Compartment/Roof Component Views Overhead Console Components 1 - S72 Sunroof Switch 2 - S88 Sunroof Ventilation Switch 3 - E37B Dome / Reading Lamps - 2nd Row 4 - K61 Sunroof Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 7730 Sunroof / Moonroof Module: Diagrams Component Connector End Views K61 Sunroof Control Module (CF5) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trunk / Liftgate Relay > Component Information > Locations Trunk / Liftgate Relay: Locations Electrical Center Identification Views X51A Fuse Block - Instrument Panel Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trunk / Liftgate Relay > Component Information > Locations > Page 7734 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Diagrams Sun Shade: Diagrams Component Connector End Views A3L Sunshade - Left A3R Sunshade - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Diagrams > Page 7740 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Diagrams > Page 7741 Sun Shade: Service and Repair Sunroof Sunshade Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair Sunroof / Moonroof Motor: Service and Repair Sunroof Window Motor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations Sunroof / Moonroof Switch: Locations Passenger Compartment/Roof Component Views Overhead Console Components 1 - S72 Sunroof Switch 2 - S88 Sunroof Ventilation Switch 3 - E37B Dome / Reading Lamps - 2nd Row 4 - K61 Sunroof Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 7748 Sunroof / Moonroof Switch: Diagrams Component Connector End Views S72 Sunroof Switch (CF5) S88 Sunroof Tilt Switch (CF5) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 7749 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 7750 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair Sunroof / Moonroof Track: Service and Repair Sunroof Housing Drain Gutter Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Sunroof Air Deflector Cover Replacement Sunroof / Moonroof Windguard: Service and Repair Sunroof Air Deflector Cover Replacement Sunroof Air Deflector Cover Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Sunroof Air Deflector Cover Replacement > Page 7758 Sunroof / Moonroof Windguard: Service and Repair Sunroof Air Deflector Replacement Sunroof Air Deflector Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Sunroof Housing Front Drain Hose Replacement Sunroof / Moonroof Drain: Service and Repair Sunroof Housing Front Drain Hose Replacement Sunroof Housing Front Drain Hose Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Sunroof Housing Front Drain Hose Replacement > Page 7763 Sunroof / Moonroof Drain: Service and Repair Sunroof Housing Rear Drain Hose Replacement Sunroof Housing Rear Drain Hose Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair Sunroof / Moonroof Frame: Service and Repair Sunroof Frame Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations Sunroof / Moonroof Module: Locations Passenger Compartment/Roof Component Views Overhead Console Components 1 - S72 Sunroof Switch 2 - S88 Sunroof Ventilation Switch 3 - E37B Dome / Reading Lamps - 2nd Row 4 - K61 Sunroof Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 7770 Sunroof / Moonroof Module: Diagrams Component Connector End Views K61 Sunroof Control Module (CF5) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments Sunroof / Moonroof Panel: Adjustments Sunroof Window Height and Opening Fit Adjustment Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments > Page 7774 Sunroof / Moonroof Panel: Service and Repair Sunroof Window Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Window Seal Replacement Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Seal Replacement Sunroof Window Seal Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Window Seal Replacement > Page 7779 Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Seal Replacement - Front Sunroof Window Seal Replacement - Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Driver or Passenger Seat Head Restraint Guide Replacement Head Rest: Service and Repair Driver or Passenger Seat Head Restraint Guide Replacement Driver or Passenger Seat Head Restraint Guide Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Driver or Passenger Seat Head Restraint Guide Replacement > Page 7785 Head Rest: Service and Repair Driver or Passenger Seat Head Restraint Replacement Driver or Passenger Seat Head Restraint Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Driver or Passenger Seat Head Restraint Guide Replacement > Page 7786 Head Rest: Service and Repair Rear Seat Head Restraint Replacement Rear Seat Head Restraint Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Driver or Passenger Seat Head Restraint Guide Replacement > Page 7787 Head Rest: Service and Repair Rear Seat Head Restraint Guide Replacement Rear Seat Head Restraint Guide Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Front Seat Tilt Adjuster Actuator Replacement Power Seat Motor: Service and Repair Front Seat Tilt Adjuster Actuator Replacement Front Seat Tilt Adjuster Actuator Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Front Seat Tilt Adjuster Actuator Replacement > Page 7796 Power Seat Motor: Service and Repair Front Seat Adjuster Actuator Replacement Front Seat Adjuster Actuator Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Front Seat Tilt Adjuster Actuator Replacement > Page 7797 Power Seat Motor: Service and Repair Driver Seat Outer Adjuster Rear Vertical Actuator Replacement Driver Seat Outer Adjuster Rear Vertical Actuator Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Replacement Power Seat Switch: Service and Repair Driver or Passenger Seat Adjuster Switch Replacement Driver or Passenger Seat Adjuster Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Replacement > Page 7802 Power Seat Switch: Service and Repair Driver Seat Adjuster Switch Replacement Driver Seat Adjuster Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Rear Seat Back Cushion Cover and Pad Replacement - Left Side Seat Back: Service and Repair Rear Seat Back Cushion Cover and Pad Replacement - Left Side Rear Seat Back Cushion Cover and Pad Replacement - Left Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Rear Seat Back Cushion Cover and Pad Replacement - Left Side > Page 7807 Seat Back: Service and Repair Rear Seat Back Cushion Cover and Pad Replacement - Right Side Rear Seat Back Cushion Cover and Pad Replacement - Right Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Rear Seat Back Cushion Cover and Pad Replacement - Left Side > Page 7808 Seat Back: Service and Repair Rear Seat Back Cushion Latch Release Knob Bezel Replacement (40 Percent Seat) Rear Seat Back Cushion Latch Release Knob Bezel Replacement (40 Percent Seat) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Rear Seat Back Cushion Cover and Pad Replacement - Left Side > Page 7809 Seat Back: Service and Repair Rear Seat Back Cushion Latch Release Knob Bezel Replacement (60 Percent Seat) Rear Seat Back Cushion Latch Release Knob Bezel Replacement (60 Percent Seat) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Rear Seat Back Cushion Cover and Pad Replacement - Left Side > Page 7810 Seat Back: Service and Repair Rear Seat Back Cushion Cover and Pad Replacement - Left Side Rear Seat Back Cushion Cover and Pad Replacement - Left Side Rear Seat Back Cushion Cover and Pad Replacement - Right Side Rear Seat Back Cushion Cover and Pad Replacement - Right Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Rear Seat Back Cushion Cover and Pad Replacement - Left Side > Page 7811 Rear Seat Back Cushion Latch Release Knob Bezel Replacement (40 Percent Seat) Rear Seat Back Cushion Latch Release Knob Bezel Replacement (40 Percent Seat) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Rear Seat Back Cushion Cover and Pad Replacement - Left Side > Page 7812 Rear Seat Back Cushion Latch Release Knob Bezel Replacement (60 Percent Seat) Rear Seat Back Cushion Latch Release Knob Bezel Replacement (60 Percent Seat) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Rear Seat Back Cushion Cover and Pad Replacement - Left Side > Page 7813 Rear Seat Back Cushion Panel Replacement (40 Percent Seat) Rear Seat Back Cushion Panel Replacement (40 Percent Seat) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Rear Seat Back Cushion Cover and Pad Replacement - Left Side > Page 7814 Rear Seat Back Cushion Panel Replacement (60 Percent Seat) Rear Seat Back Cushion Panel Replacement (60 Percent Seat) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Rear Seat Back Cushion Cover and Pad Replacement - Left Side > Page 7815 Rear Seat Back Cushion Pivot Support Replacement Rear Seat Back Cushion Pivot Support Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Rear Seat Back Cushion Cover and Pad Replacement - Left Side > Page 7816 Driver or Passenger Seat Back Cushion Cover and Pad Replacement Driver or Passenger Seat Back Cushion Cover and Pad Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Warning Replace the passenger presence system as a complete assembly to prevent possible injury to the occupant. The bladder, the pressure sensor, the seat cushion, and the control module are assembled and calibrated as a unit. Using only some of the components in the service kit will cause the passenger presence system to operate improperly. Warning Do not repair or replace the seat stitching or seams in the seat back trim cover with an internal mounted seat side airbag module. Replace the complete seat back trim cover from the OEM. Non-OEM seat stitching may cause improper airbag deployment which could result in personal injury. 1. Remove driver or passenger seat. Refer to Driver or Passenger Seat Replacement (See: Service and Repair/Removal and Replacement/Driver or Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Rear Seat Back Cushion Cover and Pad Replacement - Left Side > Page 7817 Passenger Seat Replacement). 2. Remove front seat adjuster handle, if equipped. 3. Remove front seat recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement (See: Service and Repair/Removal and Replacement/Driver or Passenger Seat Recliner Handle Replacement). 4. Remove seat cushion inner trim panel. Refer to Front Seat Cushion Inner Trim Panel Replacement (See: Seat Cushion/Service and Repair/Front Seat Cushion Inner Trim Panel Replacement). 5. Remove seat cushion outer trim panel. Refer to Front Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion/Service and Repair/Front Seat Cushion Outer Trim Panel Replacement). 6. Remove front seat head restraint guide. Refer to Driver or Passenger Seat Head Restraint Guide Replacement (See: Head Rest/Service and Repair/Driver or Passenger Seat Head Restraint Guide Replacement). 7. Detach cushion cover from backrest below. 8. Release and disconnect wiring harness plug (1), if equipped. Note: Recline the seat full rearward to allow enough access to fully remove the seatback foam. 9. Remove cushion cover (1) on backside. * Open 2 zippers on backside. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Rear Seat Back Cushion Cover and Pad Replacement - Left Side > Page 7818 * Remove the 2 tie straps from the side airbag. * Loosen cushion covering all the way around. 10. Remove front seat back cushion cover (1). * Detach cushion cover from frame (3). * Remove cushion cover (1) from Velcro. 11. Remove the seat side airbag. Refer to Driver or Passenger Seat Side Inflatable Restraint Module Replacement (See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver or Passenger Seat Side Inflatable Restraint Module Replacement). 12. Remove front seat back cushion pad (2). 13. Remove the front seat back cushion heater, if equipped. Refer to Driver or Passenger Seat Back Cushion Heater Replacement (See: Seat Heater/Service and Repair/Driver or Passenger Seat Back Cushion Heater Replacement). Installation Procedure 1. Install the front seat back cushion heater to the new cushion pad, if equipped. Refer to Driver or Passenger Seat Back Cushion Heater Replacement (See: Seat Heater/Service and Repair/Driver or Passenger Seat Back Cushion Heater Replacement). 2. Install front seat back cushion pad (2). 3. Install the seat side airbag. Refer to Driver or Passenger Seat Side Inflatable Restraint Module Replacement (See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver or Passenger Seat Side Inflatable Restraint Module Replacement). 4. Install front seat back cushion cover (1). * Install cushion cover (1) to Velcro. * Attach cushion cover to frame (3). 5. Install cushion cover (1) to backside. * Install cushion covering all the way around. * Install the 2 tie straps to the side airbag. * Close 2 zippers on backside. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Rear Seat Back Cushion Cover and Pad Replacement - Left Side > Page 7819 6. Connect and latch wiring harness plug (1), if equipped. 7. Attach cushion cover to backrest below. 8. Install front seat head restraint guide. Refer to Driver or Passenger Seat Head Restraint Guide Replacement (See: Head Rest/Service and Repair/Driver or Passenger Seat Head Restraint Guide Replacement). 9. Install seat cushion outer trim panel. Refer to Front Seat Cushion Outer Trim Panel Replacement (See: Seat Cushion/Service and Repair/Front Seat Cushion Outer Trim Panel Replacement). 10. Install seat cushion inner trim panel. Refer to Front Seat Cushion Inner Trim Panel Replacement (See: Seat Cushion/Service and Repair/Front Seat Cushion Inner Trim Panel Replacement). 11. Install front seat recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement (See: Service and Repair/Removal and Replacement/Driver or Passenger Seat Recliner Handle Replacement). 12. Install front seat adjuster handle, if equipped. 13. Install driver or passenger seat. Refer to Driver or Passenger Seat Replacement (See: Service and Repair/Removal and Replacement/Driver or Passenger Seat Replacement). Rear Seat Back Side Cushion Cover Replacement Rear Seat Back Side Cushion Cover Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Rear Seat Back Cushion Cover and Pad Replacement - Left Side > Page 7820 Rear Seat Back Cushion Hinge Replacement Rear Seat Back Cushion Hinge Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Rear Seat Back Cushion Cover and Pad Replacement - Left Side > Page 7821 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 7826 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 7827 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Inner Trim Panel Replacement Seat Cushion: Service and Repair Front Seat Cushion Inner Trim Panel Replacement Front Seat Cushion Inner Trim Panel Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Inner Trim Panel Replacement > Page 7832 Seat Cushion: Service and Repair Front Seat Cushion Outer Trim Panel Replacement Front Seat Cushion Outer Trim Panel Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Inner Trim Panel Replacement > Page 7833 Seat Cushion: Service and Repair Front Seat Cushion Cover and Pad Replacement Front Seat Cushion Cover and Pad Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Warning Replace the passenger presence system as a complete assembly to prevent possible injury to the occupant. The bladder, the pressure sensor, the seat cushion, and the control module are assembled and calibrated as a unit. Using only some of the components in the service kit will cause the passenger presence system to operate improperly. 1. Remove driver or passenger seat. Refer to Driver or Passenger Seat Replacement (See: Service and Repair/Removal and Replacement/Driver or Passenger Seat Replacement). 2. Remove front seat adjuster handle, if equipped. 3. Remove front seat recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement (See: Service and Repair/Removal and Replacement/Driver or Passenger Seat Recliner Handle Replacement). 4. Remove seat cushion inner trim panel. Refer to Front Seat Cushion Inner Trim Panel Replacement (See: Front Seat Cushion Inner Trim Panel Replacement). 5. Remove seat cushion outer trim panel. Refer to Front Seat Cushion Outer Trim Panel Replacement (See: Front Seat Cushion Outer Trim Panel Replacement). 6. Detach cushion cover from backrest below. 7. Release and disconnect wiring harness plug (1), if equipped. 8. Remove front seat backrest screw (2) (Qty: 4). 9. Remove backrest. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Inner Trim Panel Replacement > Page 7834 10. Detach cushion cover (1) from seat frame (3) all the way round. 11. Remove cushion cover (1) with pad (2) from frame (3). 12. Remove cushion cover (1) from pad (2). Installation Procedure 1. Install cushion cover (1) to pad (2). 2. Install cushion cover (1) with pad (2) to frame (3). 3. Attach cushion cover (1) from seat frame (3) all the way round. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Inner Trim Panel Replacement > Page 7835 4. Install backrest. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten screw (2) (Qty: 4). 35 Nm (26 lb ft) 6. Connect and latch wiring harness plug (1), if equipped. 7. Attach cushion cover to backrest below. 8. Install seat cushion outer trim panel. Refer to Front Seat Cushion Outer Trim Panel Replacement (See: Front Seat Cushion Outer Trim Panel Replacement). 9. Install seat cushion inner trim panel. Refer to Front Seat Cushion Inner Trim Panel Replacement (See: Front Seat Cushion Inner Trim Panel Replacement). 10. Install front seat recliner handle. Refer to Driver or Passenger Seat Recliner Handle Replacement (See: Service and Repair/Removal and Replacement/Driver or Passenger Seat Recliner Handle Replacement). 11. Install front seat adjuster handle, if equipped. 12. Install driver or passenger seat. Refer to Driver or Passenger Seat Replacement (See: Service and Repair/Removal and Replacement/Driver or Passenger Seat Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Inner Trim Panel Replacement > Page 7836 Seat Cushion: Service and Repair Rear Seat Cushion Cover and Pad Replacement Rear Seat Cushion Cover and Pad Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Inner Trim Panel Replacement > Page 7837 Seat Cushion: Service and Repair Rear Seat Cushion Replacement Rear Seat Cushion Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions Seat Fan: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7842 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7843 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7844 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7845 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7846 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7847 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7848 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7849 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7850 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7851 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7852 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7853 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7854 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7855 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7856 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7857 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7858 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7859 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7860 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7861 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7862 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7863 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7864 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7865 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7866 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7867 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7868 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7869 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7870 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7871 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7872 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7873 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7874 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7875 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7876 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7877 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7878 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7879 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7880 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7881 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7882 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7883 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7884 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7885 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7886 Seat Fan: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7887 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7888 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7889 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools EL-35616-200 - Test Light - Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A Digital Multimeter (DMM) should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The EL-35616-200 - kit is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7890 Testing for a Short to Voltage Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J-25070 - Heat Gun For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, to move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to the Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J-25070 - heat gun. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7891 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. In addition, circuit cooling spray can be used to cool down a component or circuit. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7892 For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Special Tools Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7893 EL-35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7894 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Using Snapshots in Global Diagnostic System (GDS) Overview Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7895 A snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. To record a snapshot in GDS, select, Record Snapshot, from the options at the top right portion of any of the various pages that allow snapshots to be taken (e.g. Data Display, Control Functions, etc.). When you are finished recording, select, Stop Snapshot recording. The snapshot will now be available for replay. Snapshot Replay The Snapshot Replay function allows reviews of previously recorded vehicle snapshot data. This information can be used in analysis of vehicle problems and detection of trigger error conditions. The graph function can be used to compare parameters to see if a component is functioning properly. Recorded snapshots can be selected for viewing by the following three methods: * Selecting a snapshot file from the Vehicle Home Page and clicking on the Review selection. * Double clicking on the selected snapshot from the Vehicle Home Page. * Entering the Tools selection from the Menu selection and selecting Snapshot replay. Next, open the Snapshot Manager. Double click on the snapshot file you wish to view or click on the Load Snapshot selection and select a snapshot file. Regardless of selection method, a File Loaded pop-up window will be displayed from the Snapshot Replay screen. Select OK from the pop-up window. Snapshot Play Functions There are several snapshot play functions that are used to replay recorded snapshots * The Play function is used to play the snapshot forward by clicking on this selection. A marker will move across the screen when this selection is used. All selections in this area turn grey when they are active. * The Pause function is used to pause play of the snapshot. When this selection is clicked a second time the snapshot will start playing where it left off. * The Stop function is used to stop playing the snapshot. The snapshot will start from the beginning, if Play is selected after using the Stop function. Time Control Time control is used to control the snapshot replay. This function allows selection of a specific time frame, display of different views, and control of display speed. The following functions can be selected directly under Time Control. * The Bookmark selection allows you to add a specific comment in the current display and return to this point in the future. When this option is selected, a pop-up window is displayed. Enter a bookmark name and select OK. * The Note Pad can be selected to add comments to the snapshot replay file at the current point of time. When this option is selected, a pop-up window is displayed. Enter a comment for the snapshot file and select OK. * The Load Snapshot (blue folder) opens a snapshot file and makes it ready for further analysis. This function is also available by clicking on an available snapshot file from the Snapshot Manager. * The Down Arrow displays all Time Control options when selected. Individual options can also be selected by clicking on the item you want. * The Snapshot Display Speed can be controlled by selecting this option. Slow speeds of 1/8X, 1/4X, and 1/2X can be selected. The real time speed can also be selected at 1. Faster speeds of 2X, 4X, and 8X can also be obtained by using this selection. View Selections Each View Selection provides a different way of displaying vehicle data for analysis. The following functions can be selected under Available Views: Note: The parameter name will be shown in the original language used for capture if no translation is available for the name. * Parameter List View - Displays incoming information from the snapshot file. The current value of the parameters is displayed on the screen. * Log View - Contains all the information from the snapshot file. All parameter values are listed in the order they were recorded. Specific parameters can be added or removed from a watchlist by clicking on the appropriate item. * State View - Shows the values of all parameters in a specific time frame. These values can be used for comparison with the trigger view. * Trigger View - Displays all system and user defined triggers. This function can be used when there is a combination of factors involved in a diagnostic problem. When a Trigger condition is met a caution triangle will be displayed on the screen. Triggers: * Load Triggers - Allows you to load a file containing trigger definitions. * Save Triggers - Allows you to save the trigger to your computer's hard drive. * Remove Trigger - Allows you to remove the current trigger. It will no longer be present. * Edit Trigger - Displays a pop-up window where you can modify the limits and parameters contained within a trigger. * Adds Trigger - Displays a pop-up window to configure a trigger. * DTC View - After the Play function is selected and this option is selected this function opens the list of recorded DTCs. * Line Graph View - Displays data that can be visualized against the time-axis. From this view, specific parameters can be selected for graphing by Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7896 checking the box under Selected. At the bottom of the graph there are four functions Zoom In (increase size), Zoom Out (decrease size), Bookmarks, and Pause Scrolling. Each of these functions can be accessed by clicking on them. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools EL-39200 - Digital Multimeter For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the EL-39200 - digital multimeter (DMM). This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. Note: The DMM must be used in order to perform the following procedure since the DMM can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7897 Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the DMM to the circuit. 2. Set the DMM to the V (AC) or V (DC) position. 3. Select the voltage range feature of the DMM in order to select the desired voltage range. Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 4. Select the MIN MAX function of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button until the MAX value is displayed and note the value. 8. Press the MIN MAX button until the MIN value is displayed and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools EL-35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7898 To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the EL-35616 - kit when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center. Use EL-35616 - kit to test for proper terminal contact. Failure to use EL-35616 - kit can result in improper diagnosis of the bussed electrical center. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal/terminated lead, verify that the retention force is significantly different between a known good terminal and the suspect terminal. Replace the female terminal in question. Flat Wire Connectors There are no serviceable parts for flat wire connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter into the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7899 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures - In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference or other types of electrical noise. Inspect for the following conditions: * A mis-routed harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc.-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc.-These accessories may create interference in other circuits while operating and the interference would disappear when the accessory is not operating. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7900 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, current, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 Mohm input impedance 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Current 1. Test a DC current range of 0.1 µA-10 A. 2. Test an AC current range of 0.1 µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 Mohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 Hz-199 k Hz Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7901 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 25 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the engine control module (ECM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the EL-39200. The DMM instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Special Tools EL 35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools EL 35616-20F - Fused Jumper Wire For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: A fused jumper may not protect solid state components from being damaged. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7902 The EL 35616-20F - Fused Jumper Wire includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool * J-38125-216 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7903 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7904 3. Slide the lever lock forward while pressing down on the lever lock release tab. 4. View showing depressing of the lever lock release tab. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7905 5. View of connector in released position. 6. Disconnect the connector from the component. 7. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 8. Release the rear lower half of the wiredress cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7906 9. Release the tabs that are holding the wiredress cover to the connector body. 10. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J-38125-216 can also be used to remove the nose piece. 11. Use the J-38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7907 12. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 13. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 14. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-561 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7908 4. Insert the J-38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-213 - Terminal Release Tool * J-38125-556 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7909 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7910 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7911 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J-38125-213 or the J-38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. 10. Reconnect the connector bodies. Bosch Connectors (0.64) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7912 Bosch Connectors (0.64) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7913 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7914 11. Insert the J-38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 13. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 14. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7915 Bosch Connectors (2.8 JPT) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-557 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J-38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7916 * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT) )Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock))FCI Connectors (SIR) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI (SIR)) * FEP Connectors (Steering Gear) (See: General Electrical Diagnostic Procedures/Connector Repairs/FEP Connectors (Steering Gear)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) Connector Anatomy Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7917 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7918 * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7919 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7920 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7921 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7922 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools EL-38125-580 - Terminal Release Tool Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7923 Terminal Removal Procedure Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull to Seat) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7924 Delphi Connectors (Pull To Seat) Special Tools EL-38125-580 - Terminal Release Tool Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Review the connector end view to determine the proper test probe and release tool. 5. Insert the release tool into the front of the connector body. 6. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 3. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-21 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7925 Terminal Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7926 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7927 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wire dress cover and pull the lever over and past the locks. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7928 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7929 Note: Be careful not to angle or rock the J-38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J-38125-21 tool into the round canal between the terminals cavities at the front of the connector. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7930 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7931 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7932 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7933 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J-38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7934 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-10A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J-38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7935 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (12-Way) Delphi Connectors (12-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7936 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7937 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7938 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J-38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7939 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (Steering Gear) Delphi Connectors (Steering Gear) Removal Procedure 1. Use a small flat-bladed tool to release the locking tab on the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7940 2. Push down the locking tab to release the connector. The small flat-bladed tool may need to be pushed down and angled back slightly to depress the locking tab. Pull on the connector body while releasing the locking tab to disconnect the connector. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-556 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7941 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7942 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. 7. For the larger terminals insert the J-38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J-38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7943 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 9. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 10. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. FCI (SIR) FCI Connectors (SIR) Removal Procedure Note: The orange connector position assurance (CPA) must be released first to disconnect or to connect the connector. 1. Lift the orange CPA vertically (avoid lifting on an angle to the connector) approximately 4 mm to release the connector. Use a small flat-bladed Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7944 tool to help release the orange CPA. The orange CPA can also be released manually without any tools. 2. Grab the connector on both sides and lift the connector vertically to disconnect the connector. Installation Procedure 1. Lift the orange CPA vertically approximately 4 mm before installing the connector. Use a small flat-bladed tool to help release the orange CPA. The orange CPA can also be released manually without any tools. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7945 2. Line up the connector key tabs with the initiator key slots. Grab the connector on both sides and push the connector down into the initiator connector sub assembly until fully seated. 3. After the connector is fully seated, push down the orange CPA with your thumb. Push down until the orange CPA is touching the yellow cover on the connector. FEP Connectors (Steering Gear) FEP Connectors (Steering Gear) Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7946 1. Use a small flat-bladed tool to release the locking tab on the connector. 2. Push down the locking tab to release the connector. The small flat-bladed tool may need to be pushed down and angled back slightly to depress the locking tab. Pull on the connector body while releasing the locking tab to disconnect the connector. JST Connectors JST Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7947 The JST connector family consists of seven unique connector housings differentiated by color and keying. This connector family is designed to use both 0.64 and 2.8 sized terminals. 1. While depressing the lock, remove the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7948 2. Unlock the terminal position assurance (TPA): * Position connector as shown (above) and locate TPA staging cavities. * Using connector terminal release tool J-38125-553 (1) lift the TPA into the staged position (figure 1). Perform this step on both sides of the TPA. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7949 * You will feel the TPA click into place when fully extended into the staged position. The figure above shows the TPA (1) in the staged position. 3. Release the terminal from the connector: * Position the connector as shown (above) and locate the terminal release entry canal (1) of the suspect terminal. * Insert the connector terminal release tool J-38125-553 into the entry canal with the angled side of the tool facing the connector wall containing cavity 4 (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7950 * The cavity on the left (1) is a 2.8 mm cavity and the cavity on the right (2) is a 0.64 mm cavity. * Place the tip of the connector terminal release tool onto the connector lance (3) and deflect the lance to the right (5) to release the lock. Hold this released position. * Holding the lance in the released position, slightly pull on the suspect terminal to remove it from the connector housing. The side TPA (4) is a secondary lock. 4. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 5. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-24 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7951 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7952 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7953 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7954 8. Use the J-38125-24 or the J-38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-28 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7955 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7956 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J-38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7957 locked in place by gently pulling on the wire. 3. Locate the TPA. 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7958 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-213 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7959 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7960 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7961 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J-38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7962 Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7963 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J-38125-12A - tool into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7964 7. Pressing the J-38125-12A - tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool * J-38125-13A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-bladed tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7965 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-bladed tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J-38125-13A - tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J-38125-12A - tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7966 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7967 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7968 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7969 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7970 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7971 6. Use the J-38125-12A tool to release the terminals by pressing on the tang. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool * J-38125-212 - Terminal Release Tool * J-38125-216 - Terminal Release Tool * J-38125-221 - Terminal Release Tool * J-38125-560 - Terminal Release Tool * J-38125-566 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7972 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7973 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7974 Note: During assembly the terminal position assurance (TPA) will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J-38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7975 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7976 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7977 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J-38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7978 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7979 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7980 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7981 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7982 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. 22. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 23. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool * J-38125-212 - Terminal Release Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7983 * J-38125-556 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7984 Note: Terminal position assurance (TPA) is keyed and can only be inserted in one direction. 3. Using terminal release tool J-38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7985 5. Using terminal release tool J-38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7986 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7987 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7988 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7989 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7990 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7991 * J-38125-552 - Terminal Release Tool * J-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7992 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7993 5. Once the nose piece retainers are relaxed, use the J-38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7994 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7995 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7996 2. Insert the J-38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7997 5. Insert the J-38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-24 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7998 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 7999 5. While pushing the terminal forward, insert the J-38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8000 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J-38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8001 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-215 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8002 1. While depressing the lock, pull the two connector halves apart. Note: The terminal position assurance (TPA) is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the TPA towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8003 4. View of the female half of the connector with male terminals. 5. Use the J-38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. 6. View of the female half of the connector with male terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8004 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 9. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 10. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Repairing Connector Terminals (Terminated Lead Repair) Repairing Connector Terminals (Terminated Lead Repair) Special Tools * EL-38125-10 - Splice Sleeve Crimp Tool * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs procedures. For high temperature wiring repairs, refer to High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs). Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to in Splicing Copper Wire Using Splice Sleeves to identify the correct DuraSeal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Repairing Connector Terminals (Terminal Repair) Repairing Connector Terminals (Terminal Repair) Special Tools * J-38125 - Terminal Repair Kit * J-38125-6 - Crimp Tool * J-38125-7 - Crimp Tool * J-38125-8 - Crimp Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8005 * J-38125-64 - Crimp Tool * J-38125-101 - Crimp Tool * J-38125-641 - Crimp Tool * J-38125-642 - Crimp Tool * J-38125-643 - Crimp Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Use the following repair procedures to repair each type of terminal: * For push to seat terminals, refer to Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)). * For pull to seat terminals, refer to Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)). Note: The first step for all terminal repairs is to find the connector end view in SI. Cable Seal Terminals 1. Cut off the terminal between the core and the insulation crimp to minimize any wire loss. 2. Remove the old seal. 3. Apply the correct cable seal, per the wire gauge size, from the kit. Slide the seal back along the wire to enable removal of the insulation. 4. To minimize wire loss, remove only the insulation required. 5. Using the connector end view, determine the correct crimp tool and crimp jaw. 6. Align the seal with the end of the cable insulation. 7. Position the stripped wire and seal in the terminal. 8. Hand Crimp the core wings first. 9. Hand Crimp the insulation wings around the seal and the cable. 10. Solder all of the hand crimp terminals except the Micro-Pack 100 and 0.64 sizes. Unsealed Terminals 1. Cut off the terminal between the core and the insulation crimp to minimize any wire loss. 2. To minimize wire loss, remove only the insulation required. 3. Position the stripped wire in the terminal. 4. Hand Crimp the core wings first. 5. Hand Crimp the insulation wings around the cable. 6. Solder all of the hand crimp terminals except the Micro-Pack 100 and 0.64 sizes. Micro-Pack 100W Size Terminal The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8006 the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Micro 0.64 Size Terminal The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J-38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J-38125-64 crimping tool is also designed to crimp Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8007 both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8008 7. Place the terminal into the appropriate cavity and assemble the connector. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8009 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch Special Tool * DuraSeal splice sleeves * A wire stripping tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8010 For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A terminated lead can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs in the service information connector end views or the vehicle schematics in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and EL-38125-10 - tool. For wiring repair, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. High Temperature Wiring Repairs High Temperature Wiring Repairs Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8011 Note: All wiring repairs need to be 200 mm from the heat zone. Areas of consideration would be any area located near the exhaust manifolds, catalytic converter, exhaust pipes, and turbocharged engines. Items Required * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * Terminated leads or pigtails * The correct tools to remove the terminals from the connectors Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing. * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Note: High temperature areas would be areas located near exhaust manifolds, catalytic converters, exhaust pipes, and turbocharged engines. Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8012 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. Terminated leads can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs in the service information connector end views or the vehicle schematics in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8013 the DuraSeal splice sleeves and EL-38125-10 - tool. For wiring repair, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). For connector position assurance (CPA), refer to Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks). For terminal position assurance (TPA), refer to Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks). Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except Tefzel and coaxial. Use DuraSeal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert to regional wiring gauge size. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. For high temperature wiring, slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8014 tubing will not interfere with the splice procedure. 5. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 6. Use the splice sleeve crimp tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 7. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 8. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 9. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4, 6 and 15 for the opposite end of the splice. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8015 10. Using the heat torch, apply heat to the crimped area of the barrel. 11. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. High Temperature Wiring Repairs Use the following procedures to perform high temperature wiring repairs: 1. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 2. Using the heat torch, apply heat to the high temperature heat shrink tubing. 3. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 4. Replace any reflective tape and clips that may have been removed during the repair. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8016 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8017 * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8018 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8019 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8020 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. Note: Some terminals have a lever that must be disengaged before the terminal can be released. * Insert the terminal release tool into the cavity. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8021 Special Tools * EL-38125-10 - Splice Sleeve Crimp Tool * EL-38125-580 - Terminal Release Tool Kit * J-38125-5 - Ultra Torch * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8022 (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 8023 Seat Fan: Electrical Diagrams Heated/Cooled Seat Schematics KA1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Specifications Seat Heater: Specifications Fastener Tightening Specifications Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions Seat Heater: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8029 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8030 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8031 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8032 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8033 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8034 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8035 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8036 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8037 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8038 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8039 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8040 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8041 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8042 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8043 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8044 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8045 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8046 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8047 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8048 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8049 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8050 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8051 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8052 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8053 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8054 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8055 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8056 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8057 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8058 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8059 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8060 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8061 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8062 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8063 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8064 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8065 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8066 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8067 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8068 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8069 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8070 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8071 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8072 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8073 Seat Heater: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8074 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8075 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8076 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools EL-35616-200 - Test Light - Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A Digital Multimeter (DMM) should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The EL-35616-200 - kit is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8077 Testing for a Short to Voltage Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J-25070 - Heat Gun For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, to move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to the Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J-25070 - heat gun. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8078 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. In addition, circuit cooling spray can be used to cool down a component or circuit. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8079 For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Special Tools Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8080 EL-35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8081 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Using Snapshots in Global Diagnostic System (GDS) Overview Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8082 A snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. To record a snapshot in GDS, select, Record Snapshot, from the options at the top right portion of any of the various pages that allow snapshots to be taken (e.g. Data Display, Control Functions, etc.). When you are finished recording, select, Stop Snapshot recording. The snapshot will now be available for replay. Snapshot Replay The Snapshot Replay function allows reviews of previously recorded vehicle snapshot data. This information can be used in analysis of vehicle problems and detection of trigger error conditions. The graph function can be used to compare parameters to see if a component is functioning properly. Recorded snapshots can be selected for viewing by the following three methods: * Selecting a snapshot file from the Vehicle Home Page and clicking on the Review selection. * Double clicking on the selected snapshot from the Vehicle Home Page. * Entering the Tools selection from the Menu selection and selecting Snapshot replay. Next, open the Snapshot Manager. Double click on the snapshot file you wish to view or click on the Load Snapshot selection and select a snapshot file. Regardless of selection method, a File Loaded pop-up window will be displayed from the Snapshot Replay screen. Select OK from the pop-up window. Snapshot Play Functions There are several snapshot play functions that are used to replay recorded snapshots * The Play function is used to play the snapshot forward by clicking on this selection. A marker will move across the screen when this selection is used. All selections in this area turn grey when they are active. * The Pause function is used to pause play of the snapshot. When this selection is clicked a second time the snapshot will start playing where it left off. * The Stop function is used to stop playing the snapshot. The snapshot will start from the beginning, if Play is selected after using the Stop function. Time Control Time control is used to control the snapshot replay. This function allows selection of a specific time frame, display of different views, and control of display speed. The following functions can be selected directly under Time Control. * The Bookmark selection allows you to add a specific comment in the current display and return to this point in the future. When this option is selected, a pop-up window is displayed. Enter a bookmark name and select OK. * The Note Pad can be selected to add comments to the snapshot replay file at the current point of time. When this option is selected, a pop-up window is displayed. Enter a comment for the snapshot file and select OK. * The Load Snapshot (blue folder) opens a snapshot file and makes it ready for further analysis. This function is also available by clicking on an available snapshot file from the Snapshot Manager. * The Down Arrow displays all Time Control options when selected. Individual options can also be selected by clicking on the item you want. * The Snapshot Display Speed can be controlled by selecting this option. Slow speeds of 1/8X, 1/4X, and 1/2X can be selected. The real time speed can also be selected at 1. Faster speeds of 2X, 4X, and 8X can also be obtained by using this selection. View Selections Each View Selection provides a different way of displaying vehicle data for analysis. The following functions can be selected under Available Views: Note: The parameter name will be shown in the original language used for capture if no translation is available for the name. * Parameter List View - Displays incoming information from the snapshot file. The current value of the parameters is displayed on the screen. * Log View - Contains all the information from the snapshot file. All parameter values are listed in the order they were recorded. Specific parameters can be added or removed from a watchlist by clicking on the appropriate item. * State View - Shows the values of all parameters in a specific time frame. These values can be used for comparison with the trigger view. * Trigger View - Displays all system and user defined triggers. This function can be used when there is a combination of factors involved in a diagnostic problem. When a Trigger condition is met a caution triangle will be displayed on the screen. Triggers: * Load Triggers - Allows you to load a file containing trigger definitions. * Save Triggers - Allows you to save the trigger to your computer's hard drive. * Remove Trigger - Allows you to remove the current trigger. It will no longer be present. * Edit Trigger - Displays a pop-up window where you can modify the limits and parameters contained within a trigger. * Adds Trigger - Displays a pop-up window to configure a trigger. * DTC View - After the Play function is selected and this option is selected this function opens the list of recorded DTCs. * Line Graph View - Displays data that can be visualized against the time-axis. From this view, specific parameters can be selected for graphing by Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8083 checking the box under Selected. At the bottom of the graph there are four functions Zoom In (increase size), Zoom Out (decrease size), Bookmarks, and Pause Scrolling. Each of these functions can be accessed by clicking on them. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools EL-39200 - Digital Multimeter For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the EL-39200 - digital multimeter (DMM). This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. Note: The DMM must be used in order to perform the following procedure since the DMM can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8084 Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the DMM to the circuit. 2. Set the DMM to the V (AC) or V (DC) position. 3. Select the voltage range feature of the DMM in order to select the desired voltage range. Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 4. Select the MIN MAX function of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button until the MAX value is displayed and note the value. 8. Press the MIN MAX button until the MIN value is displayed and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools EL-35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8085 To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the EL-35616 - kit when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center. Use EL-35616 - kit to test for proper terminal contact. Failure to use EL-35616 - kit can result in improper diagnosis of the bussed electrical center. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal/terminated lead, verify that the retention force is significantly different between a known good terminal and the suspect terminal. Replace the female terminal in question. Flat Wire Connectors There are no serviceable parts for flat wire connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter into the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8086 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures - In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference or other types of electrical noise. Inspect for the following conditions: * A mis-routed harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc.-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc.-These accessories may create interference in other circuits while operating and the interference would disappear when the accessory is not operating. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8087 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, current, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 Mohm input impedance 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Current 1. Test a DC current range of 0.1 µA-10 A. 2. Test an AC current range of 0.1 µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 Mohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 Hz-199 k Hz Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8088 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 25 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the engine control module (ECM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the EL-39200. The DMM instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Special Tools EL 35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools EL 35616-20F - Fused Jumper Wire For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: A fused jumper may not protect solid state components from being damaged. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8089 The EL 35616-20F - Fused Jumper Wire includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool * J-38125-216 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8090 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8091 3. Slide the lever lock forward while pressing down on the lever lock release tab. 4. View showing depressing of the lever lock release tab. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8092 5. View of connector in released position. 6. Disconnect the connector from the component. 7. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 8. Release the rear lower half of the wiredress cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8093 9. Release the tabs that are holding the wiredress cover to the connector body. 10. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J-38125-216 can also be used to remove the nose piece. 11. Use the J-38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8094 12. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 13. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 14. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-561 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8095 4. Insert the J-38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-213 - Terminal Release Tool * J-38125-556 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8096 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8097 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8098 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J-38125-213 or the J-38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. 10. Reconnect the connector bodies. Bosch Connectors (0.64) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8099 Bosch Connectors (0.64) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8100 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8101 11. Insert the J-38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 13. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 14. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8102 Bosch Connectors (2.8 JPT) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-557 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J-38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8103 * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT) )Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock))FCI Connectors (SIR) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI (SIR)) * FEP Connectors (Steering Gear) (See: General Electrical Diagnostic Procedures/Connector Repairs/FEP Connectors (Steering Gear)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) Connector Anatomy Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8104 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8105 * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8106 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8107 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8108 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8109 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools EL-38125-580 - Terminal Release Tool Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8110 Terminal Removal Procedure Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull to Seat) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8111 Delphi Connectors (Pull To Seat) Special Tools EL-38125-580 - Terminal Release Tool Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Review the connector end view to determine the proper test probe and release tool. 5. Insert the release tool into the front of the connector body. 6. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 3. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-21 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8112 Terminal Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8113 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8114 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wire dress cover and pull the lever over and past the locks. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8115 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8116 Note: Be careful not to angle or rock the J-38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J-38125-21 tool into the round canal between the terminals cavities at the front of the connector. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8117 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8118 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8119 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8120 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J-38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8121 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-10A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J-38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8122 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (12-Way) Delphi Connectors (12-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8123 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8124 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8125 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J-38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8126 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (Steering Gear) Delphi Connectors (Steering Gear) Removal Procedure 1. Use a small flat-bladed tool to release the locking tab on the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8127 2. Push down the locking tab to release the connector. The small flat-bladed tool may need to be pushed down and angled back slightly to depress the locking tab. Pull on the connector body while releasing the locking tab to disconnect the connector. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-556 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8128 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8129 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. 7. For the larger terminals insert the J-38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J-38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8130 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 9. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 10. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. FCI (SIR) FCI Connectors (SIR) Removal Procedure Note: The orange connector position assurance (CPA) must be released first to disconnect or to connect the connector. 1. Lift the orange CPA vertically (avoid lifting on an angle to the connector) approximately 4 mm to release the connector. Use a small flat-bladed Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8131 tool to help release the orange CPA. The orange CPA can also be released manually without any tools. 2. Grab the connector on both sides and lift the connector vertically to disconnect the connector. Installation Procedure 1. Lift the orange CPA vertically approximately 4 mm before installing the connector. Use a small flat-bladed tool to help release the orange CPA. The orange CPA can also be released manually without any tools. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8132 2. Line up the connector key tabs with the initiator key slots. Grab the connector on both sides and push the connector down into the initiator connector sub assembly until fully seated. 3. After the connector is fully seated, push down the orange CPA with your thumb. Push down until the orange CPA is touching the yellow cover on the connector. FEP Connectors (Steering Gear) FEP Connectors (Steering Gear) Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8133 1. Use a small flat-bladed tool to release the locking tab on the connector. 2. Push down the locking tab to release the connector. The small flat-bladed tool may need to be pushed down and angled back slightly to depress the locking tab. Pull on the connector body while releasing the locking tab to disconnect the connector. JST Connectors JST Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8134 The JST connector family consists of seven unique connector housings differentiated by color and keying. This connector family is designed to use both 0.64 and 2.8 sized terminals. 1. While depressing the lock, remove the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8135 2. Unlock the terminal position assurance (TPA): * Position connector as shown (above) and locate TPA staging cavities. * Using connector terminal release tool J-38125-553 (1) lift the TPA into the staged position (figure 1). Perform this step on both sides of the TPA. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8136 * You will feel the TPA click into place when fully extended into the staged position. The figure above shows the TPA (1) in the staged position. 3. Release the terminal from the connector: * Position the connector as shown (above) and locate the terminal release entry canal (1) of the suspect terminal. * Insert the connector terminal release tool J-38125-553 into the entry canal with the angled side of the tool facing the connector wall containing cavity 4 (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8137 * The cavity on the left (1) is a 2.8 mm cavity and the cavity on the right (2) is a 0.64 mm cavity. * Place the tip of the connector terminal release tool onto the connector lance (3) and deflect the lance to the right (5) to release the lock. Hold this released position. * Holding the lance in the released position, slightly pull on the suspect terminal to remove it from the connector housing. The side TPA (4) is a secondary lock. 4. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 5. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-24 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8138 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8139 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8140 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8141 8. Use the J-38125-24 or the J-38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-28 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8142 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8143 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J-38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8144 locked in place by gently pulling on the wire. 3. Locate the TPA. 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8145 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-213 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8146 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8147 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8148 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J-38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8149 Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8150 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J-38125-12A - tool into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8151 7. Pressing the J-38125-12A - tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool * J-38125-13A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-bladed tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8152 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-bladed tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J-38125-13A - tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J-38125-12A - tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8153 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8154 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8155 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8156 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8157 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8158 6. Use the J-38125-12A tool to release the terminals by pressing on the tang. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool * J-38125-212 - Terminal Release Tool * J-38125-216 - Terminal Release Tool * J-38125-221 - Terminal Release Tool * J-38125-560 - Terminal Release Tool * J-38125-566 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8159 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8160 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8161 Note: During assembly the terminal position assurance (TPA) will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J-38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8162 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8163 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8164 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J-38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8165 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8166 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8167 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8168 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8169 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. 22. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 23. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool * J-38125-212 - Terminal Release Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8170 * J-38125-556 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8171 Note: Terminal position assurance (TPA) is keyed and can only be inserted in one direction. 3. Using terminal release tool J-38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8172 5. Using terminal release tool J-38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8173 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8174 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8175 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8176 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8177 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8178 * J-38125-552 - Terminal Release Tool * J-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8179 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8180 5. Once the nose piece retainers are relaxed, use the J-38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8181 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8182 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8183 2. Insert the J-38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8184 5. Insert the J-38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-24 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8185 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8186 5. While pushing the terminal forward, insert the J-38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8187 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J-38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8188 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-215 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8189 1. While depressing the lock, pull the two connector halves apart. Note: The terminal position assurance (TPA) is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the TPA towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8190 4. View of the female half of the connector with male terminals. 5. Use the J-38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. 6. View of the female half of the connector with male terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8191 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 9. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 10. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Repairing Connector Terminals (Terminated Lead Repair) Repairing Connector Terminals (Terminated Lead Repair) Special Tools * EL-38125-10 - Splice Sleeve Crimp Tool * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs procedures. For high temperature wiring repairs, refer to High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs). Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to in Splicing Copper Wire Using Splice Sleeves to identify the correct DuraSeal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Repairing Connector Terminals (Terminal Repair) Repairing Connector Terminals (Terminal Repair) Special Tools * J-38125 - Terminal Repair Kit * J-38125-6 - Crimp Tool * J-38125-7 - Crimp Tool * J-38125-8 - Crimp Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8192 * J-38125-64 - Crimp Tool * J-38125-101 - Crimp Tool * J-38125-641 - Crimp Tool * J-38125-642 - Crimp Tool * J-38125-643 - Crimp Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Use the following repair procedures to repair each type of terminal: * For push to seat terminals, refer to Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)). * For pull to seat terminals, refer to Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)). Note: The first step for all terminal repairs is to find the connector end view in SI. Cable Seal Terminals 1. Cut off the terminal between the core and the insulation crimp to minimize any wire loss. 2. Remove the old seal. 3. Apply the correct cable seal, per the wire gauge size, from the kit. Slide the seal back along the wire to enable removal of the insulation. 4. To minimize wire loss, remove only the insulation required. 5. Using the connector end view, determine the correct crimp tool and crimp jaw. 6. Align the seal with the end of the cable insulation. 7. Position the stripped wire and seal in the terminal. 8. Hand Crimp the core wings first. 9. Hand Crimp the insulation wings around the seal and the cable. 10. Solder all of the hand crimp terminals except the Micro-Pack 100 and 0.64 sizes. Unsealed Terminals 1. Cut off the terminal between the core and the insulation crimp to minimize any wire loss. 2. To minimize wire loss, remove only the insulation required. 3. Position the stripped wire in the terminal. 4. Hand Crimp the core wings first. 5. Hand Crimp the insulation wings around the cable. 6. Solder all of the hand crimp terminals except the Micro-Pack 100 and 0.64 sizes. Micro-Pack 100W Size Terminal The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8193 the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Micro 0.64 Size Terminal The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J-38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J-38125-64 crimping tool is also designed to crimp Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8194 both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8195 7. Place the terminal into the appropriate cavity and assemble the connector. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8196 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch Special Tool * DuraSeal splice sleeves * A wire stripping tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8197 For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A terminated lead can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs in the service information connector end views or the vehicle schematics in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and EL-38125-10 - tool. For wiring repair, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. High Temperature Wiring Repairs High Temperature Wiring Repairs Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8198 Note: All wiring repairs need to be 200 mm from the heat zone. Areas of consideration would be any area located near the exhaust manifolds, catalytic converter, exhaust pipes, and turbocharged engines. Items Required * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * Terminated leads or pigtails * The correct tools to remove the terminals from the connectors Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing. * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Note: High temperature areas would be areas located near exhaust manifolds, catalytic converters, exhaust pipes, and turbocharged engines. Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8199 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. Terminated leads can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs in the service information connector end views or the vehicle schematics in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8200 the DuraSeal splice sleeves and EL-38125-10 - tool. For wiring repair, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). For connector position assurance (CPA), refer to Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks). For terminal position assurance (TPA), refer to Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks). Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except Tefzel and coaxial. Use DuraSeal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert to regional wiring gauge size. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. For high temperature wiring, slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8201 tubing will not interfere with the splice procedure. 5. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 6. Use the splice sleeve crimp tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 7. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 8. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 9. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4, 6 and 15 for the opposite end of the splice. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8202 10. Using the heat torch, apply heat to the crimped area of the barrel. 11. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. High Temperature Wiring Repairs Use the following procedures to perform high temperature wiring repairs: 1. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 2. Using the heat torch, apply heat to the high temperature heat shrink tubing. 3. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 4. Replace any reflective tape and clips that may have been removed during the repair. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8203 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8204 * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8205 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8206 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8207 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. Note: Some terminals have a lever that must be disengaged before the terminal can be released. * Insert the terminal release tool into the cavity. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8208 Special Tools * EL-38125-10 - Splice Sleeve Crimp Tool * EL-38125-580 - Terminal Release Tool Kit * J-38125-5 - Ultra Torch * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8209 (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8210 Seat Heater: Connector Views Component Connector End Views E14A Seat Heating Element - Driver Back (KA1) E14C Seat Heating Element - Passenger Back (KA1) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8211 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8212 Seat Heater: Electrical Diagrams Heated/Cooled Seat Schematics KA1 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 8213 Seat Heater: Description and Operation Heated Seats Description and Operation Heated Seat Components The driver and passenger heated seats consist of the following components: * Left heated seat switch * Right heated seat switch * HVAC control * Seat heating control module * Driver seat cushion heating element * Driver seat back heating element * Driver seat cushion temperature sensor * Passenger seat cushion heating element * Passenger seat back heating element * Passenger seat cushion temperature sensor Power and Ground Battery positive voltage is supplied at all times to the seat heating control module through a 30 A fuse located in the underhood fuse block. This voltage is used by the module to supply power to the seat heating elements. Ground for the module is provided at G307. Heated Seat Operation The driver and passenger heated seats are controlled by a single seat heating control module that is located under the driver seat cushion. Both heated seats are controlled by separate heated seat switches that are located in the HVAC control. When a heated seat switch is pressed, a serial data message is sent from the HVAC control to the HVAC control module indicating the heated seat command. The HVAC control module then serves as a gateway to transmit the message to the seat heating control module via the serial data line. In response to this signal, the seat heating control module applies battery positive voltage through the element supply voltage circuit to the appropriate seat heating elements. The seat heating control module then sends a serial data message back to the HVAC control module to gateway the information to the HVAC control to either illuminate or turn off the appropriate temperature indicator. Temperature Regulation When the engine ON, the heated seats will initialize in the OFF state. With each activation of the heated seat switch, the seat heating control module will cycle the temperature setting in the following manner: HIGH, MEDIUM, LOW, and OFF. The seat heating control module monitors the seat temperature through the temperature sensor signal circuit and the temperature sensor (thermistor) that is located in the seat cushion. The temperature sensor is a variable resistor, it's resistance changes as the temperature of the seat changes. When the temperature sensor resistance indicates to the seat heating control module that the seat has reached the desired temperature, the module opens the ground path of the seat heating elements through the heated seat element control circuit. The module will then cycle the element control circuit open and closed in order to maintain the desired temperature. Load Management The electrical power management function is designed to monitor the vehicle electrical load and determine when the battery is potentially in a high discharge condition. The heated seat system is one of the vehicle loads that is subject to reduction during a battery discharge condition. For more information on load management refer to Electrical Power Management Description and Operation (See: Starting and Charging/Description and Operation/Electrical Power Management). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling Seat Heater: Testing and Inspection Symptoms - Seat Heating and Cooling Symptoms - Seat Heating and Cooling Note: The following steps must be completed before using the symptom tables. 1. When diagnosing a heated seat system condition perform the Diagnostic System Check Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) , before using the symptom tables in order to verify that all of the following are true: * There are no DTCs set. * The control module(s) can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Heated Seats Description and Operation (See: Description and Operation). Visual/Physical Inspection * Inspect for aftermarket devices which could affect the operation of the power seats. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. * Inspect the seat adjuster track for conditions which may cause binding or objects within the seat adjustment range which obstruct movement or interfere with wiring. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). Symptom List Refer to the Front Heated Seat Malfunction (See: Front Heated Seat Malfunction) diagnostic procedure in order to diagnose the symptom. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 8216 Seat Heater: Testing and Inspection Front Heated Seat Malfunction Front Heated Seat Malfunction Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The driver and passenger heated seats are controlled by separate heated seat switches that are located in the HVAC control. When a heated seat switch is pressed, a serial data message is sent from the HVAC control to the HVAC control module indicating the heated seat command. The HVAC control module then serves as a gateway to transmit the message to the seat heating control module via the serial data line. In response to this message, the seat heating control module applies battery positive voltage through the element supply voltage circuit to the appropriate seat heating elements. The seat heating control module then sends a serial data message back to the HVAC control module to gateway the information to the HVAC control to either illuminate or turn off the appropriate temperature indicator. Reference Information Schematic Reference Heated/Cooled Seat Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Description and Operation Heated Seats Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 8217 Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification 1. Engine ON, observe the scan tool Driver Seat Heating/Venting/Cooling Mode parameter while pressing the driver HEATED seat switch. The reading should change between Off and Back & Cushion Heat. ‹› If not the specified value, replace the A26 HVAC control. 2. Observe the scan tool Passenger Seat Heating/Venting/Cooling Mode parameter while pressing the passenger HEATED seat switch. The reading should change between Off and Back & Cushion Heat. ‹› If not the specified value, replace the A26 HVAC control. 3. If all scan tool parameter readings are normal, there are no DTCs set, and the driver and/or passenger heated seat is inoperative, replace the K29 seat heating control module. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Heater and Air Conditioning Control Replacement (See: Heating and Air Conditioning/Control Assembly/Service and Repair/HVAC - Automatic ) * Control Module References (See: Testing and Inspection/Programming and Relearning) for seat heating control module replacement, setup, and programming Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Driver Seat Cushion Heater Replacement Seat Heater: Service and Repair Driver Seat Cushion Heater Replacement Driver Seat Cushion Heater Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Driver Seat Cushion Heater Replacement > Page 8220 Seat Heater: Service and Repair Passenger Seat Cushion Heater Replacement Passenger Seat Cushion Heater Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Driver Seat Cushion Heater Replacement > Page 8221 Seat Heater: Service and Repair Driver or Passenger Seat Back Cushion Heater Replacement Driver or Passenger Seat Back Cushion Heater Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams Seat Heater Control Module: Diagrams Component Connector End Views K29 Seat Heating Control Module X2 (KA1) K29 Seat Heating Control Module X3 (KA1) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 8225 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 8226 Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Rear Seat Back Latch Replacement (40 Percent Seat) Seat Latch: Service and Repair Rear Seat Back Latch Replacement (40 Percent Seat) Rear Seat Back Latch Replacement (40 Percent Seat) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Rear Seat Back Latch Replacement (40 Percent Seat) > Page 8231 Seat Latch: Service and Repair Rear Seat Back Latch Replacement (60 Percent Seat) Rear Seat Back Latch Replacement (60 Percent Seat) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Ajar Switch > Component Information > Diagrams Hood Ajar Switch: Diagrams Component Connector End Views B55 Hood Ajar Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Locations Pedal Positioning Sensor: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Locations > Page 8240 Pedal Positioning Sensor: Diagrams Component Connector End Views B22 Brake Pedal Position Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Service and Repair > Brake Pedal Position Sensor Calibration Pedal Positioning Sensor: Service and Repair Brake Pedal Position Sensor Calibration Brake Pedal Position Sensor Calibration Calibration Criteria Note: Do not apply the brake pedal during the brake pedal position sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the brake pedal position sensor calibration must be repeated. Brake pedal position sensor calibration must be performed after the brake pedal position sensor or body control module (BCM) have been serviced. The calibration procedure will set the brake pedal position sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data. Calibration Procedure 1. Apply the parking brake. 2. Place the transmission in the PARK position. 3. Install a scan tool. 4. Navigate to the Module Diagnosis menu. 5. Clear all BCM DTCs before proceeding. 6. Navigate to the Configuration/Reset Functions menu of the BCM. 7. Select Brake Pedal Position Sensor Learn. 8. Select the Brake Pedal Position Sensor Learn procedure and follow the directions displayed on the screen. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Service and Repair > Brake Pedal Position Sensor Calibration > Page 8243 Pedal Positioning Sensor: Service and Repair Brake Pedal Position Sensor Replacement Brake Pedal Position Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations Instrument Panel/Center Console Component Views Center of the I/P Components 1 - P16 Instrument Cluster 2 - P17 Info Display Module 3 - S26 Hazard Lamps Switch 4 - A26 HVAC Control 5 - S13D Door Lock Switch - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 8247 Power Door Lock Switch: Diagrams Component Connector End Views S13D Door Lock Switch - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 8248 Power Door Lock Switch: Service and Repair Door Lock Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Door Component Views Driver Door Components 1 - S79D Window Switch - Driver 2 - S52 Outside Rearview Mirror Switch 3 - A9A Outside Rearview Mirror - Driver 4 - P19G Speaker - Left Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 8252 Power Mirror Switch: Diagrams Component Connector End Views S52 Outside Rearview Mirror Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 8253 Power Mirror Switch: Service and Repair Outside Remote Control Rearview Mirror Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Replacement Power Seat Switch: Service and Repair Driver or Passenger Seat Adjuster Switch Replacement Driver or Passenger Seat Adjuster Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Replacement > Page 8258 Power Seat Switch: Service and Repair Driver Seat Adjuster Switch Replacement Driver Seat Adjuster Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Sunroof / Moonroof Switch: Locations Passenger Compartment/Roof Component Views Overhead Console Components 1 - S72 Sunroof Switch 2 - S88 Sunroof Ventilation Switch 3 - E37B Dome / Reading Lamps - 2nd Row 4 - K61 Sunroof Control Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 8262 Sunroof / Moonroof Switch: Diagrams Component Connector End Views S72 Sunroof Switch (CF5) S88 Sunroof Tilt Switch (CF5) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 8263 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 8264 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations Trunk / Liftgate Switch: Locations Luggage Compartment/Rear of Vehicle Component Views Trunk Components 2 of 2 1 - E7 License Plate Lamp 2 - S58A Rear Compartment Lid Unlatch Switch - Exterior 3 - E7 License Plate Lamp Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Service and Repair Sound Proofing / Insulation: Service and Repair Front Fender Insulator Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Splash Guard > Component Information > Service and Repair > Front Compartment Splash Shield Replacement Splash Guard: Service and Repair Front Compartment Splash Shield Replacement Front Compartment Splash Shield Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Splash Guard > Component Information > Service and Repair > Front Compartment Splash Shield Replacement > Page 8275 Splash Guard: Service and Repair Front Compartment Insulator Replacement Front Compartment Insulator Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information > Service and Repair > Aero Shutter Front Bumper Fascia Air Deflector Replacement Air Dam: Service and Repair Aero Shutter Front Bumper Fascia Air Deflector Replacement Aero Shutter Front Bumper Fascia Air Deflector Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information > Service and Repair > Aero Shutter Front Bumper Fascia Air Deflector Replacement > Page 8281 Air Dam: Service and Repair Underbody Rear Air Deflector Replacement Underbody Rear Air Deflector Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair Spoiler: Service and Repair Rear End Spoiler Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front or Rear Side Door Lower Weatherstrip Replacement Front Door Weatherstrip: Service and Repair Front or Rear Side Door Lower Weatherstrip Replacement Front or Rear Side Door Lower Weatherstrip Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front or Rear Side Door Lower Weatherstrip Replacement > Page 8295 Front Door Weatherstrip: Service and Repair Front Side Door Weatherstrip Replacement - Door Side Front Side Door Weatherstrip Replacement - Door Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front or Rear Side Door Lower Weatherstrip Replacement > Page 8296 Front Door Weatherstrip: Service and Repair Front Side Door Weatherstrip Replacement - Body Side Front Side Door Weatherstrip Replacement - Body Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front or Rear Side Door Lower Weatherstrip Replacement > Page 8297 Front Door Weatherstrip: Service and Repair Front Side Door Window Weatherstrip Replacement Front Side Door Window Weatherstrip Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair Hood Weatherstrip: Service and Repair Hood Rear Weatherstrip Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Side Door Weatherstrip Replacement - Body Side Rear Door Weatherstrip: Service and Repair Rear Side Door Weatherstrip Replacement - Body Side Rear Side Door Weatherstrip Replacement - Body Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Side Door Weatherstrip Replacement - Body Side > Page 8305 Rear Door Weatherstrip: Service and Repair Rear Side Door Weatherstrip Replacement - Door Side Rear Side Door Weatherstrip Replacement - Door Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Side Door Weatherstrip Replacement - Body Side > Page 8306 Rear Door Weatherstrip: Service and Repair Rear Side Door Window Weatherstrip Replacement Rear Side Door Window Weatherstrip Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Side Door Weatherstrip Replacement - Body Side > Page 8307 Rear Door Weatherstrip: Service and Repair Front or Rear Side Door Lower Weatherstrip Replacement Front or Rear Side Door Lower Weatherstrip Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair Rear Door Window Glass Weatherstrip: Service and Repair Rear Side Door Window Channel Insulator Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Window Seal Replacement Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Seal Replacement Sunroof Window Seal Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Window Seal Replacement > Page 8315 Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Seal Replacement - Front Sunroof Window Seal Replacement - Front Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Rear Compartment Lid Weatherstrip Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair Cruise Control Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair Cruise Control Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component Information > Diagrams Air Bag Deactivation Indicator: Diagrams Component Connector End Views P14 Passenger Air Bag Disable Indicator Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component Information > Diagrams > Page 8331 Air Bag Deactivation Indicator: Service and Repair Inflatable Restraint Instrument Panel Module Indicator Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8336 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8337 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8338 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8339 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8340 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8341 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8342 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8343 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8344 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8345 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8346 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8347 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8348 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8349 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8350 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8351 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8352 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8353 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8354 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8355 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8356 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8357 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8358 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8359 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8360 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8361 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8362 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8363 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8364 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8365 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8366 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8367 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8368 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8369 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8370 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8371 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8372 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8373 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8374 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8375 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8376 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8377 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8378 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8379 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8380 Cigarette Lighter: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8381 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8382 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8383 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools EL-35616-200 - Test Light - Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A Digital Multimeter (DMM) should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The EL-35616-200 - kit is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8384 Testing for a Short to Voltage Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J-25070 - Heat Gun For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, to move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to the Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J-25070 - heat gun. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8385 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. In addition, circuit cooling spray can be used to cool down a component or circuit. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8386 For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Special Tools Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8387 EL-35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8388 Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Using Snapshots in Global Diagnostic System (GDS) Overview Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8389 A snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. To record a snapshot in GDS, select, Record Snapshot, from the options at the top right portion of any of the various pages that allow snapshots to be taken (e.g. Data Display, Control Functions, etc.). When you are finished recording, select, Stop Snapshot recording. The snapshot will now be available for replay. Snapshot Replay The Snapshot Replay function allows reviews of previously recorded vehicle snapshot data. This information can be used in analysis of vehicle problems and detection of trigger error conditions. The graph function can be used to compare parameters to see if a component is functioning properly. Recorded snapshots can be selected for viewing by the following three methods: * Selecting a snapshot file from the Vehicle Home Page and clicking on the Review selection. * Double clicking on the selected snapshot from the Vehicle Home Page. * Entering the Tools selection from the Menu selection and selecting Snapshot replay. Next, open the Snapshot Manager. Double click on the snapshot file you wish to view or click on the Load Snapshot selection and select a snapshot file. Regardless of selection method, a File Loaded pop-up window will be displayed from the Snapshot Replay screen. Select OK from the pop-up window. Snapshot Play Functions There are several snapshot play functions that are used to replay recorded snapshots * The Play function is used to play the snapshot forward by clicking on this selection. A marker will move across the screen when this selection is used. All selections in this area turn grey when they are active. * The Pause function is used to pause play of the snapshot. When this selection is clicked a second time the snapshot will start playing where it left off. * The Stop function is used to stop playing the snapshot. The snapshot will start from the beginning, if Play is selected after using the Stop function. Time Control Time control is used to control the snapshot replay. This function allows selection of a specific time frame, display of different views, and control of display speed. The following functions can be selected directly under Time Control. * The Bookmark selection allows you to add a specific comment in the current display and return to this point in the future. When this option is selected, a pop-up window is displayed. Enter a bookmark name and select OK. * The Note Pad can be selected to add comments to the snapshot replay file at the current point of time. When this option is selected, a pop-up window is displayed. Enter a comment for the snapshot file and select OK. * The Load Snapshot (blue folder) opens a snapshot file and makes it ready for further analysis. This function is also available by clicking on an available snapshot file from the Snapshot Manager. * The Down Arrow displays all Time Control options when selected. Individual options can also be selected by clicking on the item you want. * The Snapshot Display Speed can be controlled by selecting this option. Slow speeds of 1/8X, 1/4X, and 1/2X can be selected. The real time speed can also be selected at 1. Faster speeds of 2X, 4X, and 8X can also be obtained by using this selection. View Selections Each View Selection provides a different way of displaying vehicle data for analysis. The following functions can be selected under Available Views: Note: The parameter name will be shown in the original language used for capture if no translation is available for the name. * Parameter List View - Displays incoming information from the snapshot file. The current value of the parameters is displayed on the screen. * Log View - Contains all the information from the snapshot file. All parameter values are listed in the order they were recorded. Specific parameters can be added or removed from a watchlist by clicking on the appropriate item. * State View - Shows the values of all parameters in a specific time frame. These values can be used for comparison with the trigger view. * Trigger View - Displays all system and user defined triggers. This function can be used when there is a combination of factors involved in a diagnostic problem. When a Trigger condition is met a caution triangle will be displayed on the screen. Triggers: * Load Triggers - Allows you to load a file containing trigger definitions. * Save Triggers - Allows you to save the trigger to your computer's hard drive. * Remove Trigger - Allows you to remove the current trigger. It will no longer be present. * Edit Trigger - Displays a pop-up window where you can modify the limits and parameters contained within a trigger. * Adds Trigger - Displays a pop-up window to configure a trigger. * DTC View - After the Play function is selected and this option is selected this function opens the list of recorded DTCs. * Line Graph View - Displays data that can be visualized against the time-axis. From this view, specific parameters can be selected for graphing by Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8390 checking the box under Selected. At the bottom of the graph there are four functions Zoom In (increase size), Zoom Out (decrease size), Bookmarks, and Pause Scrolling. Each of these functions can be accessed by clicking on them. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools EL-39200 - Digital Multimeter For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the EL-39200 - digital multimeter (DMM). This feature allows you to manipulate the circuit without having to watch the DMM. The DMM will generate an audible tone when a change is detected. Note: The DMM must be used in order to perform the following procedure since the DMM can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the DMM to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8391 Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the DMM to the circuit. 2. Set the DMM to the V (AC) or V (DC) position. 3. Select the voltage range feature of the DMM in order to select the desired voltage range. Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 4. Select the MIN MAX function of the DMM. The DMM displays 100 ms RECORD and emits an audible tone (beep). 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button until the MAX value is displayed and note the value. 8. Press the MIN MAX button until the MIN value is displayed and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools EL-35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8392 To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the EL-35616 - kit when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center. Use EL-35616 - kit to test for proper terminal contact. Failure to use EL-35616 - kit can result in improper diagnosis of the bussed electrical center. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal/terminated lead, verify that the retention force is significantly different between a known good terminal and the suspect terminal. Replace the female terminal in question. Flat Wire Connectors There are no serviceable parts for flat wire connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter into the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8393 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures - In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference or other types of electrical noise. Inspect for the following conditions: * A mis-routed harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc.-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc.-These accessories may create interference in other circuits while operating and the interference would disappear when the accessory is not operating. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8394 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, current, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 Mohm input impedance 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Current 1. Test a DC current range of 0.1 µA-10 A. 2. Test an AC current range of 0.1 µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 Mohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 Hz-199 k Hz Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8395 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 25 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the engine control module (ECM), should only be tested with a 10 MOhms or higher impedance digital multimeter such as the EL-39200. The DMM instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Special Tools EL 35616 - Terminal Test Probe Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools EL 35616-20F - Fused Jumper Wire For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: A fused jumper may not protect solid state components from being damaged. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8396 The EL 35616-20F - Fused Jumper Wire includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool * J-38125-216 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8397 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8398 3. Slide the lever lock forward while pressing down on the lever lock release tab. 4. View showing depressing of the lever lock release tab. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8399 5. View of connector in released position. 6. Disconnect the connector from the component. 7. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 8. Release the rear lower half of the wiredress cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8400 9. Release the tabs that are holding the wiredress cover to the connector body. 10. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J-38125-216 can also be used to remove the nose piece. 11. Use the J-38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8401 12. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 13. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 14. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-561 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8402 4. Insert the J-38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-213 - Terminal Release Tool * J-38125-556 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8403 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8404 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8405 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J-38125-213 or the J-38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. 10. Reconnect the connector bodies. Bosch Connectors (0.64) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8406 Bosch Connectors (0.64) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8407 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8408 11. Insert the J-38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 13. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 14. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8409 Bosch Connectors (2.8 JPT) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-557 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J-38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8410 * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT) )Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock))FCI Connectors (SIR) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI (SIR)) * FEP Connectors (Steering Gear) (See: General Electrical Diagnostic Procedures/Connector Repairs/FEP Connectors (Steering Gear)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) Connector Anatomy Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8411 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8412 * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8413 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8414 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8415 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8416 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools EL-38125-580 - Terminal Release Tool Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8417 Terminal Removal Procedure Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Pull to Seat) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8418 Delphi Connectors (Pull To Seat) Special Tools EL-38125-580 - Terminal Release Tool Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Review the connector end view to determine the proper test probe and release tool. 5. Insert the release tool into the front of the connector body. 6. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 3. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-21 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8419 Terminal Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8420 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8421 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wire dress cover and pull the lever over and past the locks. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8422 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8423 Note: Be careful not to angle or rock the J-38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J-38125-21 tool into the round canal between the terminals cavities at the front of the connector. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8424 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8425 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8426 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8427 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J-38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8428 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-10A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J-38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8429 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (12-Way) Delphi Connectors (12-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8430 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8431 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8432 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J-38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8433 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 11. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Delphi Connectors (Steering Gear) Delphi Connectors (Steering Gear) Removal Procedure 1. Use a small flat-bladed tool to release the locking tab on the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8434 2. Push down the locking tab to release the connector. The small flat-bladed tool may need to be pushed down and angled back slightly to depress the locking tab. Pull on the connector body while releasing the locking tab to disconnect the connector. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-556 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8435 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8436 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. 7. For the larger terminals insert the J-38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J-38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8437 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 9. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 10. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. FCI (SIR) FCI Connectors (SIR) Removal Procedure Note: The orange connector position assurance (CPA) must be released first to disconnect or to connect the connector. 1. Lift the orange CPA vertically (avoid lifting on an angle to the connector) approximately 4 mm to release the connector. Use a small flat-bladed Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8438 tool to help release the orange CPA. The orange CPA can also be released manually without any tools. 2. Grab the connector on both sides and lift the connector vertically to disconnect the connector. Installation Procedure 1. Lift the orange CPA vertically approximately 4 mm before installing the connector. Use a small flat-bladed tool to help release the orange CPA. The orange CPA can also be released manually without any tools. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8439 2. Line up the connector key tabs with the initiator key slots. Grab the connector on both sides and push the connector down into the initiator connector sub assembly until fully seated. 3. After the connector is fully seated, push down the orange CPA with your thumb. Push down until the orange CPA is touching the yellow cover on the connector. FEP Connectors (Steering Gear) FEP Connectors (Steering Gear) Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8440 1. Use a small flat-bladed tool to release the locking tab on the connector. 2. Push down the locking tab to release the connector. The small flat-bladed tool may need to be pushed down and angled back slightly to depress the locking tab. Pull on the connector body while releasing the locking tab to disconnect the connector. JST Connectors JST Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8441 The JST connector family consists of seven unique connector housings differentiated by color and keying. This connector family is designed to use both 0.64 and 2.8 sized terminals. 1. While depressing the lock, remove the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8442 2. Unlock the terminal position assurance (TPA): * Position connector as shown (above) and locate TPA staging cavities. * Using connector terminal release tool J-38125-553 (1) lift the TPA into the staged position (figure 1). Perform this step on both sides of the TPA. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8443 * You will feel the TPA click into place when fully extended into the staged position. The figure above shows the TPA (1) in the staged position. 3. Release the terminal from the connector: * Position the connector as shown (above) and locate the terminal release entry canal (1) of the suspect terminal. * Insert the connector terminal release tool J-38125-553 into the entry canal with the angled side of the tool facing the connector wall containing cavity 4 (2). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8444 * The cavity on the left (1) is a 2.8 mm cavity and the cavity on the right (2) is a 0.64 mm cavity. * Place the tip of the connector terminal release tool onto the connector lance (3) and deflect the lance to the right (5) to release the lock. Hold this released position. * Holding the lance in the released position, slightly pull on the suspect terminal to remove it from the connector housing. The side TPA (4) is a secondary lock. 4. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 5. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-24 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8445 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8446 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8447 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8448 8. Use the J-38125-24 or the J-38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-28 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8449 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8450 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J-38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8451 locked in place by gently pulling on the wire. 3. Locate the TPA. 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8452 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-213 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8453 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8454 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8455 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J-38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8456 Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8457 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J-38125-12A - tool into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8458 7. Pressing the J-38125-12A - tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool * J-38125-13A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-bladed tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8459 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-bladed tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J-38125-13A - tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J-38125-12A - tool to release the terminals by inserting the tool into the terminal release cavity. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8460 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8461 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8462 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8463 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8464 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8465 6. Use the J-38125-12A tool to release the terminals by pressing on the tang. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 8. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 9. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool * J-38125-212 - Terminal Release Tool * J-38125-216 - Terminal Release Tool * J-38125-221 - Terminal Release Tool * J-38125-560 - Terminal Release Tool * J-38125-566 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8466 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8467 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8468 Note: During assembly the terminal position assurance (TPA) will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J-38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8469 6. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8470 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8471 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J-38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8472 12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8473 14. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8474 16. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8475 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8476 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. 22. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 23. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool * J-38125-212 - Terminal Release Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8477 * J-38125-556 - Terminal Release Tool * J-38125-560 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8478 Note: Terminal position assurance (TPA) is keyed and can only be inserted in one direction. 3. Using terminal release tool J-38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8479 5. Using terminal release tool J-38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8480 7. Using terminal release tool J-38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8481 9. Using terminal release tool J-38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8482 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8483 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8484 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-12A - Terminal Release Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8485 * J-38125-552 - Terminal Release Tool * J-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8486 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8487 5. Once the nose piece retainers are relaxed, use the J-38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8488 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8489 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure After the terminal is replaced, perform the following procedure in order to insert the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-11A - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8490 2. Insert the J-38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8491 5. Insert the J-38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-24 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8492 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8493 5. While pushing the terminal forward, insert the J-38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-553 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8494 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J-38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8495 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. 7. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 8. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools * EL-38125-580 - Terminal Release Tool Kit * J-38125-215 - Terminal Release Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Terminal Removal Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8496 1. While depressing the lock, pull the two connector halves apart. Note: The terminal position assurance (TPA) is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the TPA towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8497 4. View of the female half of the connector with male terminals. 5. Use the J-38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. 6. View of the female half of the connector with male terminals. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8498 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. 9. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 10. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Repairing Connector Terminals (Terminated Lead Repair) Repairing Connector Terminals (Terminated Lead Repair) Special Tools * EL-38125-10 - Splice Sleeve Crimp Tool * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs procedures. For high temperature wiring repairs, refer to High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs). Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to in Splicing Copper Wire Using Splice Sleeves to identify the correct DuraSeal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Repairing Connector Terminals (Terminal Repair) Repairing Connector Terminals (Terminal Repair) Special Tools * J-38125 - Terminal Repair Kit * J-38125-6 - Crimp Tool * J-38125-7 - Crimp Tool * J-38125-8 - Crimp Tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8499 * J-38125-64 - Crimp Tool * J-38125-101 - Crimp Tool * J-38125-641 - Crimp Tool * J-38125-642 - Crimp Tool * J-38125-643 - Crimp Tool For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Use the following repair procedures to repair each type of terminal: * For push to seat terminals, refer to Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)). * For pull to seat terminals, refer to Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way))Delphi Connectors (Steering Gear) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Steering Gear)). Note: The first step for all terminal repairs is to find the connector end view in SI. Cable Seal Terminals 1. Cut off the terminal between the core and the insulation crimp to minimize any wire loss. 2. Remove the old seal. 3. Apply the correct cable seal, per the wire gauge size, from the kit. Slide the seal back along the wire to enable removal of the insulation. 4. To minimize wire loss, remove only the insulation required. 5. Using the connector end view, determine the correct crimp tool and crimp jaw. 6. Align the seal with the end of the cable insulation. 7. Position the stripped wire and seal in the terminal. 8. Hand Crimp the core wings first. 9. Hand Crimp the insulation wings around the seal and the cable. 10. Solder all of the hand crimp terminals except the Micro-Pack 100 and 0.64 sizes. Unsealed Terminals 1. Cut off the terminal between the core and the insulation crimp to minimize any wire loss. 2. To minimize wire loss, remove only the insulation required. 3. Position the stripped wire in the terminal. 4. Hand Crimp the core wings first. 5. Hand Crimp the insulation wings around the cable. 6. Solder all of the hand crimp terminals except the Micro-Pack 100 and 0.64 sizes. Micro-Pack 100W Size Terminal The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8500 the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Micro 0.64 Size Terminal The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J-38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J-38125-64 crimping tool is also designed to crimp Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8501 both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8502 7. Place the terminal into the appropriate cavity and assemble the connector. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8503 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch Special Tool * DuraSeal splice sleeves * A wire stripping tool Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8504 For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A terminated lead can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs in the service information connector end views or the vehicle schematics in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and EL-38125-10 - tool. For wiring repair, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. High Temperature Wiring Repairs High Temperature Wiring Repairs Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8505 Note: All wiring repairs need to be 200 mm from the heat zone. Areas of consideration would be any area located near the exhaust manifolds, catalytic converter, exhaust pipes, and turbocharged engines. Items Required * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * Terminated leads or pigtails * The correct tools to remove the terminals from the connectors Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing. * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Note: High temperature areas would be areas located near exhaust manifolds, catalytic converters, exhaust pipes, and turbocharged engines. Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8506 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. Terminated leads can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs in the service information connector end views or the vehicle schematics in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8507 the DuraSeal splice sleeves and EL-38125-10 - tool. For wiring repair, refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). For connector position assurance (CPA), refer to Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks). For terminal position assurance (TPA), refer to Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks). Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools * EL-38125-10 - Splice Sleeve Crimping Tool * J 38125-5 - Ultra Torch * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except Tefzel and coaxial. Use DuraSeal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert to regional wiring gauge size. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. For high temperature wiring, slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8508 tubing will not interfere with the splice procedure. 5. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 6. Use the splice sleeve crimp tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 7. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 8. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 9. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4, 6 and 15 for the opposite end of the splice. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8509 10. Using the heat torch, apply heat to the crimped area of the barrel. 11. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. High Temperature Wiring Repairs Use the following procedures to perform high temperature wiring repairs: 1. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 2. Using the heat torch, apply heat to the high temperature heat shrink tubing. 3. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 4. Replace any reflective tape and clips that may have been removed during the repair. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8510 Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8511 * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8512 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8513 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8514 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. Note: Some terminals have a lever that must be disengaged before the terminal can be released. * Insert the terminal release tool into the cavity. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) (See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminated Lead Repair))Repairing Connector Terminals (Terminal Repair) ( See: General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals (Terminal Repair)) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8515 Special Tools * EL-38125-10 - Splice Sleeve Crimp Tool * EL-38125-580 - Terminal Release Tool Kit * J-38125-5 - Ultra Torch * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8516 (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8517 Cigarette Lighter: Connector Views Component Connector End Views E32 Cigar Lighter Receptacle Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8518 Cigarette Lighter: Electrical Diagrams Cigar Lighter/Power Outlet Schematics Cigar Lighter and Power Outlet Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair Compass: Service and Repair Instrument Cluster Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Restraint Systems/Air Bag Systems/Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 8526 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Restraint Systems/Air Bag Systems/Diagrams/Electrical Diagrams ) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Description and Operation Door/Trunk Ajar Indicator/Lamp: Description and Operation Door Ajar Indicator Description and Operation Door Ajar Indicator System Components The door ajar indicator system consists of the following components: * Body control module (BCM) * Instrument cluster * Driver door latch * Passenger door latch * Left rear door latch * Right rear door latch * Driver window motor * Passenger window switch * Left rear window switch * Right rear window switch Driver Door Ajar The driver window motor supplies a 12 volt signal to the door ajar switch within the door latch, when the driver door is open the door ajar switch closes pulling the 12 volts signal low. When the driver window motor detects the drop in the 12 volt signal circuit, it will then communicate this status to the BCM via local interconnect network (LIN) bus. The BCM communicates with the instrument cluster via serial data message. The instrument panel cluster, upon receipt of this serial data message, will illuminate the driver door ajar indicator and also send a serial data message to the radio to activate the door ajar audible warning when the vehicle speed is greater then 8 km/h (5 MPH). All Passenger Doors Ajar The passenger window motor, the left rear window switch and right rear window switches each supplies a 12 volt signal to their respective door ajar switch within the door latch, when the a door is open the door ajar switch closes pulling the 12 volts signal low. When the passenger window motor, the left rear window switch or right rear window detects the drop in the 12 volt signal circuit, it will then communicate this status to the BCM via local interconnect network (LIN) bus. The BCM communicates with the instrument cluster via serial data message. The instrument panel cluster, upon receipt of this serial data message, will illuminate the appropriate door ajar indicator and also send a serial data message to the radio to activate the door ajar audible warning when the vehicle speed is greater then 8 km/h (5 MPH). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations Driver/Vehicle Information Display: Locations Instrument Panel/Center Console Component Views Center of the I/P Components 1 - P16 Instrument Cluster 2 - P17 Info Display Module 3 - S26 Hazard Lamps Switch 4 - A26 HVAC Control 5 - S13D Door Lock Switch - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations > Page 8533 Driver/Vehicle Information Display: Diagrams Component Connector End Views P17 Info Display Module (UAG or UFD) P17 Info Display Module (UDN) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations > Page 8534 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations > Page 8535 Driver/Vehicle Information Display: Service and Repair Driver Information Display Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair Fuel Gauge Sender: Service and Repair Fuel Sender Assembly Replacement Removal Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning: Refer to Safety Goggles and Fuel Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions/Safety Goggles and Fuel Warning). Caution: Use care while handling the fuel sender to prevent damage and incorrect fuel level readings. 1. Remove the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Tank Fuel Pump Module Replacement). 2. Disconnect the fuel sender assembly wiring harness plugs (1). 3. Unclip the 2 fuel sender retainer pins. 4. Remove the fuel sender assembly (2). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Page 8539 1. Install the fuel sender assembly (2). 2. Connect the fuel sender assembly wiring harness plugs (1). 3. Install the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Tank Fuel Pump Module Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Hood Ajar Switch > Component Information > Diagrams Hood Ajar Switch: Diagrams Component Connector End Views B55 Hood Ajar Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Restraint Systems/Air Bag Systems/Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 8547 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Restraint Systems/Air Bag Systems/Diagrams/Electrical Diagrams ) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 8552 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 8553 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 8554 Customer TPMS Information Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 8555 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 8556 Frequently Asked Questions Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module (ECM) turns the MIL ON by grounding the MIL control circuit. Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams/Powertrain Management/System Diagram) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) DTC Type Reference Powertrain Diagnostic Trouble Code (DTC) Type Definitions (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Powertrain Diagnostic Trouble Code (DTC) Type Definitions) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Circuit/System Verification 1. Ignition ON, observe the DTC information with a scan tool. Verify that DTCs U0073 00, U0100 00, or U0155 00 are not set. ‹› If any of the DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle). 2. Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool. Circuit/System Testing Ignition ON, verify that the P16 Instrument Cluster warning indicators are illuminated. If the P16 Instrument Cluster warning indicators are not illuminated, test the P16 Instrument Cluster ignition circuit terminal 31 for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the P16 Instrument Cluster. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Page 8560 * Instrument Cluster Replacement (See: Compass/Service and Repair) * Control Module References (See: Testing and Inspection/Programming and Relearning)for ECM replacement, setup, and programming Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide Odometer: Technical Service Bulletins Instruments - IPC Odometer Programming Reference Guide INFORMATION Bulletin No.: 07-08-49-020D Date: December 06, 2010 Subject: IPC Odometer Programming Method Quick Reference Guide Models: 2003-2011 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: This bulletin applies to vehicles sold in the U.S. and Canada Only. Supercede: This bulletin is being revised to add information for the 2011 model year and add new 2011 vehicles. Please discard Corporate Bulletin Number 07-08-49-020C (Section 08 - Body and Accessories). The purpose of this bulletin is to provide a reference guide to help identify which season odometer programming method to use after replacing the instrument panel cluster (IPC). The three season odometer programming methods in use today are listed below. In addition, this reference guide lists the component where the season odometer value is stored. The season odometer value may be stored in the IPC, the driver information center (DIC) or the integrated body control module (IBCM), also commonly called a body control module (BCM). Season Odometer Programming Methods in Use Today 1. IPC reprogramming and setup using the service programming system (SPS). 2. Odometer setup at the electronic service center (ESC) when using an exchange IPC/DIC. 3. Tech 2(R) - The Tech 2 is used to set up a replacement BCM, which includes loading the odometer value that is displayed and stored in the IPC. A replacement IPC will display the previously stored vehicle odometer value, communicated from the BCM, after cycling the ignition or driving the vehicle. *The odometer programming is integrated as part of the BCM programming procedure. It is not a stand-alone event. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 8565 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 8566 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 8567 Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair Engine Oil LIfe System When to Change Engine Oil This vehicle has a computer system that indicates when to change the engine oil and filter. This is based on engine revolutions and engine temperature, and not on mileage. Based on driving conditions, the mileage at which an oil change is indicated can vary considerably. For the oil life system to work properly, the system must be reset every time the oil is changed. When the system has calculated that oil life has been diminished, it indicates that an oil change is necessary. A CHANGE ENGINE OIL SOON DIC message or Code 82 DIC message comes on. Engine Oil Messages. Change the oil as soon as possible within the next 1 000 km (600 mi). It is possible that, if driving under the best conditions, the oil life system might indicate that an oil change is not necessary for up to a year. The engine oil and filter must be changed at least once a year and, at this time, the system must be reset. It is also important to check the oil regularly over the course of an oil drain interval and keep it at the proper level. If the system is ever reset accidentally, the oil must be changed at 5 000 km (3,000 mi) since the last oil change. Remember to reset the oil life system whenever the oil is changed. How to Reset the Engine Oil Life System Reset the system whenever the engine oil is changed so that the system can calculate the next engine oil change. To reset the system: 1. Using the DIC MENU button and thumbwheel, scroll until you reach REMAINING OIL LIFE on the DIC (oil can symbol with % sign for Canada). 2. Press the SET button to reset the oil life at 100%. When prompted, use the thumbwheel to highlight YES or NO. Press the SET/CLEAR button to confirm. Be careful not to reset the oil life display accidentally at any time other than after the oil is changed. It cannot be reset accurately. If the CHANGE ENGINE OIL SOON DIC message or Code 82 DIC message comes back on when the vehicle is started, the engine oil life system has not reset. Repeat the procedure. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Powertrain Component Views Engine Components - Right Front (LUJ) 1 - Q6E Camshaft Position Actuator Solenoid Valve - Exhaust 2 - B23E Camshaft Position Sensor Exhaust 3 - B37 Engine Oil Pressure Switch 4 - B52A Heated Oxygen Sensor 1 5 - Q42 Turbocharger Wastegate Solenoid Valve 6 - Q2 A/C Compressor Clutch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Service and Repair Outside Temperature Display Sensor: Service and Repair Ambient Air Temperature Gauge Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair Fuel Gauge Sender: Service and Repair Fuel Sender Assembly Replacement Removal Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning: Refer to Safety Goggles and Fuel Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions/Safety Goggles and Fuel Warning). Caution: Use care while handling the fuel sender to prevent damage and incorrect fuel level readings. 1. Remove the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Tank Fuel Pump Module Replacement). 2. Disconnect the fuel sender assembly wiring harness plugs (1). 3. Unclip the 2 fuel sender retainer pins. 4. Remove the fuel sender assembly (2). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Page 8585 1. Install the fuel sender assembly (2). 2. Connect the fuel sender assembly wiring harness plugs (1). 3. Install the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Tank Fuel Pump Module Replacement). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Hood Ajar Switch > Component Information > Diagrams Hood Ajar Switch: Diagrams Component Connector End Views B55 Hood Ajar Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Service and Repair Outside Temperature Display Sensor: Service and Repair Ambient Air Temperature Gauge Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair Automatic or Manual Transmission Control Lever Trim Cover Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 8603 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 8604 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 8605 Customer TPMS Information Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 8606 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 8607 Frequently Asked Questions Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 8616 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: If any of the following tire pressure sensor components are found to be damage, replace the damaged components. 4. Remove the tire pressure sensor indicator cap and deflate the tire. 5. Remove tire pressure sensor indicator nut (4). Note: When removing the tire pressure sensor, DO NOT re-use the seal, replace with new. 6. Remove the tire pressure sensor seal (3), the washer (2) and the tire pressure sensor (1). Installation Procedure Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 8617 1. Clean the area around the mounting point for the tire pressure sensor. 2. Install the washer (2) and the seal (3) on the tire pressure sensor (1). 3. Install the tire pressure sensor (1) on the wheel. 4. Start the nut (4) by hand. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: When installing the tire pressure sensor and the nut, position the tire pressure sensor so that it is parallel to the inside wheel surface while torquing. 5. Install the nut (2) on the tire pressure sensor (1). Tighten the nut (2) to 7 Nm (62 lb in). 6. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). 7. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 8618 and Repair). 8. Lower the vehicle. 9. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Service and Repair/Tire Pressure Indicator Sensor Learn). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Diagrams Transmission Shift Position Indicator Lamp: Diagrams Component Connector End Views P2 Automatic Transmission Shift Lever Position Indicator Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ambient Light Sensor: Locations Instrument Panel/Center Console Component Views Behind the Center of the I/P Components 2 of 4 1 - B10B Ambient Light/Sunload Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 8626 Ambient Light Sensor: Diagrams Component Connector End Views B10B Ambient Light/Sunload Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Manual Transmission Component Views Backup Lamp Switch: Locations Manual Transmission Component Views Manual Transmission Component Views Clutch Housing Components - Left Hand View 1 - Front Differential Carrier Flange Seal 2 - Front Differential Carrier Flange 3 - Front Wheel Drive Shaft Oil Seal 4 - Front Differential Carrier Flange Bolts (Qty: 4) 5 - Front Differential Carrier Flange Bolt Washers (Qty: 4) 6 - Transmission Oil Drain Plug 7 - Backup Lamp Switch Washer 8 - Backup Lamp Switch 9 - Clutch Actuator Cylinder Pipe Elbow 10 - Clutch Actuator Cylinder Pipe Sleeve Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Manual Transmission Component Views > Page 8632 Backup Lamp Switch: Locations Powertrain Component Views Powertrain Component Views Transmission Components (MF3 or MZ0) 1 - B16 Backup Lamp Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 8633 Backup Lamp Switch: Service and Repair M32 - Manual Transmission Backup Lamp Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information > Service and Repair Backup Light Bulb: Service and Repair Backup Lamp Bulb Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Brake Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 8641 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Page 8642 Brake Lamp: Diagrams Component Connector End Views E5AA Tail/Stop Lamp - Left E5AB Tail/Stop Lamp - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Page 8643 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Bulb > Component Information > Service and Repair Cargo Lamp Bulb: Service and Repair Cargo Lamp Bulb Replacement (Notchback) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams Center Mounted Brake Lamp: Diagrams Component Connector End Views E6 Center High Mounted Brake Lamp Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Page 8651 Center Mounted Brake Lamp: Service and Repair High Mount Stop Lamp Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams Glove Box Lamp: Diagrams Component Connector End Views E27 Instrument Panel Compartment Lamp Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service and Repair > Instrument Panel Compartment Lamp Replacement Glove Box Lamp: Service and Repair Instrument Panel Compartment Lamp Replacement Instrument Panel Compartment Lamp Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service and Repair > Instrument Panel Compartment Lamp Replacement > Page 8658 Glove Box Lamp: Service and Repair Instrument Panel Compartment Lamp Bulb Replacement Instrument Panel Compartment Lamp Bulb Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair Dome Lamp Bulb: Service and Repair Dome Lamp Bulb Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair Fog/Driving Lamp Bulb: Service and Repair Front Fog Lamp Bulb Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 8670 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 8671 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 8672 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations Instrument Panel/Center Console Component Views Center of the I/P Components 1 - P16 Instrument Cluster 2 - P17 Info Display Module 3 - S26 Hazard Lamps Switch 4 - A26 HVAC Control 5 - S13D Door Lock Switch - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 8677 Hazard Warning Switch: Diagrams Component Connector End Views S26 Hazard Lamps Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 8678 Hazard Warning Switch: Service and Repair Hazard Warning Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair Headlamp Bulb Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Alignment Actuator > Component Information > Locations > Right Front of the Vehicle Components 2 of 2 Headlamp Alignment Actuator: Locations Right Front of the Vehicle Components 2 of 2 Front of Vehicle/Engine Compartment Component Views Right Front of the Vehicle Components 2 of 2 1 - M29R Headlamp Leveling Actuator - Right 2 - E13R Headlamp Assembly - Right 3 - E4P Park/Turn Signal Lamp - Right 4 - G104 Engine Compartment - Front Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Alignment Actuator > Component Information > Locations > Right Front of the Vehicle Components 2 of 2 > Page 8687 Headlamp Alignment Actuator: Locations Left Front of the Vehicle Components Front of Vehicle/Engine Compartment Component Views Left Front of the Vehicle Components 1 - E4N Park/Turn Signal Lamp - Left 2 - E13L Headlamp Assembly - Left 3 - M29L Headlamp Leveling Actuator - Left 4 - G101 Engine Compartment - Front Left 5 - G103 Engine Compartment Front Left Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Sensor > Component Information > Service and Repair Headlamp Dimmer Sensor: Service and Repair Headlamp Automatic Control Ambient Light Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Lens > Component Information > Technical Service Bulletins > Lighting - Headlamp Polycarbonate Lens Damage Prevention Headlamp Lens: Technical Service Bulletins Lighting - Headlamp Polycarbonate Lens Damage Prevention INFORMATION Bulletin No.: 02-08-42-001D Date: June 21, 2010 Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior Polycarbonate Headlamp Lenses Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and to revise the warning statements. Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories). The bulletin is being issued to make dealers and customers aware of chemical damage that may be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types of headlamp lenses. This material is used because of its temperature and high impact resistance. A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when treating a vehicle with any type of chemical, such as those recommended for rail dust removal. Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash soaps in too high a concentration may also attribute to this condition. This could result in the need to replace the entire headlamp housing. Warning Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses. Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are on. This action restricts the amount of heat dissipated by the headlamps. Warning Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it could cause the lens to deform. This damage can also be caused by aftermarket shields that are often tinted in color. Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins. This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks. In more extreme cases, it will begin to melt the lens of the headlamp. Notice Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are not covered under the new vehicle warranty. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8698 Headlamp Switch: Diagrams Component Connector End Views S30 Headlamp Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8699 Headlamp Switch: Service and Repair Headlamp Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations High Beam Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations > Page 8703 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations > Page 8704 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations > Page 8705 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 8710 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 8711 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 8712 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair Steering Wheel Horn Contact Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Service and Repair > Rear License Plate Lamp Bulb Replacement License Plate Lamp: Service and Repair Rear License Plate Lamp Bulb Replacement Rear License Plate Lamp Bulb Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Service and Repair > Rear License Plate Lamp Bulb Replacement > Page 8720 License Plate Lamp: Service and Repair Rear License Plate Lamp Replacement Rear License Plate Lamp Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair Map Light Bulb: Service and Repair Reading Lamp Bulb Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair Marker Lamp Bulb: Service and Repair Front Side Marker Lamp Bulb Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Parking Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 8733 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Technical Service Bulletins > Page 8734 Parking Lamp: Diagrams Component Connector End Views E4N Park/Turn Signal Lamp - Left E4P Park/Turn Signal Lamp - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Technical Service Bulletins > Page 8735 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 8740 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 8741 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 8742 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations High Beam Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 8746 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 8747 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 8748 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 8752 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 8753 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 8754 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Tail Lamp Control Module > Component Information > Service and Repair Tail Lamp Control Module: Service and Repair Tail Lamp Control Module with Bulb Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ambient Light Sensor: Locations Instrument Panel/Center Console Component Views Behind the Center of the I/P Components 2 of 4 1 - B10B Ambient Light/Sunload Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 8762 Ambient Light Sensor: Diagrams Component Connector End Views B10B Ambient Light/Sunload Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Manual Transmission Component Views Backup Lamp Switch: Locations Manual Transmission Component Views Manual Transmission Component Views Clutch Housing Components - Left Hand View 1 - Front Differential Carrier Flange Seal 2 - Front Differential Carrier Flange 3 - Front Wheel Drive Shaft Oil Seal 4 - Front Differential Carrier Flange Bolts (Qty: 4) 5 - Front Differential Carrier Flange Bolt Washers (Qty: 4) 6 - Transmission Oil Drain Plug 7 - Backup Lamp Switch Washer 8 - Backup Lamp Switch 9 - Clutch Actuator Cylinder Pipe Elbow 10 - Clutch Actuator Cylinder Pipe Sleeve Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Manual Transmission Component Views > Page 8767 Backup Lamp Switch: Locations Powertrain Component Views Powertrain Component Views Transmission Components (MF3 or MZ0) 1 - B16 Backup Lamp Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 8768 Backup Lamp Switch: Service and Repair M32 - Manual Transmission Backup Lamp Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Combination Switch: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 8772 Combination Switch: Diagrams Component Connector End Views S78 Turn Signal/Multi-Function Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations Instrument Panel/Center Console Component Views Center of the I/P Components 1 - P16 Instrument Cluster 2 - P17 Info Display Module 3 - S26 Hazard Lamps Switch 4 - A26 HVAC Control 5 - S13D Door Lock Switch - Driver Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 8776 Hazard Warning Switch: Diagrams Component Connector End Views S26 Hazard Lamps Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 8777 Hazard Warning Switch: Service and Repair Hazard Warning Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Sensor > Component Information > Service and Repair Headlamp Dimmer Sensor: Service and Repair Headlamp Automatic Control Ambient Light Sensor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8784 Headlamp Switch: Diagrams Component Connector End Views S30 Headlamp Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8785 Headlamp Switch: Service and Repair Headlamp Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair Steering Wheel Horn Contact Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 8792 Turn Signal Switch: Diagrams Component Connector End Views S78 Turn Signal/Multi-Function Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair Tail Light Bulb: Service and Repair Tail Lamp Bulb Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp Control Module > Component Information > Service and Repair Tail Lamp Control Module: Service and Repair Tail Lamp Control Module with Bulb Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations Combination Switch: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 8804 Combination Switch: Diagrams Component Connector End Views S78 Turn Signal/Multi-Function Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Turn Signal Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 8809 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 8810 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 8811 Turn Signal Lamp: Diagrams Component Connector End Views E4LR Turn Signal Lamp - Left Rear E4N Park/Turn Signal Lamp - Left Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 8812 E4P Park/Turn Signal Lamp - Right Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 8813 E4RR Turn Signal Lamp - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 8814 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 8815 Turn Signal Lamp: Service and Repair Front Side Turn Signal Lamp Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Instrument Panel/Center Console Component Views Lower Left of the I/P Components 1 - S30 Headlamp Switch 2 - B25B Clutch Pedal Position Sensor 3 - S78 Turn Signal / Multi-Function Switch 4 - B99 Steering Wheel Angle Sensor 5 - K89 Immobilizer Control Module 6 B107 Accelerator Pedal Position Sensor 7 - B22 Brake Pedal Position Sensor 8 - X84 Data Link Connector Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 8819 Turn Signal Switch: Diagrams Component Connector End Views S78 Turn Signal/Multi-Function Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 8825 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 8826 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 8827 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 8832 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 8833 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 8834 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations Door Component Views Driver Door Components 1 - S79D Window Switch - Driver 2 - S52 Outside Rearview Mirror Switch 3 - A9A Outside Rearview Mirror - Driver 4 - P19G Speaker - Left Front Front Passenger Door Components Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 8839 1 - A9B Outside Rearview Mirror - Passenger 2 - S79P Window Switch - Passenger 3 - M74P Window Motor - Passenger 4 - P19U Speaker - Right Front Left Rear Passenger Side Door Components Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 8840 1 - B27LR Door Handle Switch - Left Rear 2 - S79LR Window Switch - Left Rear 3 - M74LR Window Motor - Left Right Rear Passenger Side Door Components Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 8841 1 - S79RR Window Switch - Right Rear 2 - B27RR Door Handle Switch - Right Rear 3 - M74RR Window Motor - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 8842 Power Window Switch: Diagrams Component Connector End Views S79D Window Switch - Driver (AEC) S79D Window Switch - Driver (AXG) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 8843 S79LR Window Switch - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 8844 S79P Window Switch - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 8845 S79RR Window Switch - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 8846 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Multifunction Switch Replacement Power Window Switch: Service and Repair Front Side Door Window and Multifunction Switch Replacement Front Side Door Window and Multifunction Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Multifunction Switch Replacement > Page 8849 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement Rear Side Door Window Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Multifunction Switch Replacement > Page 8850 Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Right Side Front Side Door Window Switch Replacement - Right Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Multifunction Switch Replacement > Page 8851 Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Left Side Front Side Door Window Switch Replacement - Left Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair Front Side Door Window Regulator Motor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair Rear Door Window Motor: Service and Repair Rear Side Door Window Regulator Motor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations Power Window Switch: Locations Door Component Views Driver Door Components 1 - S79D Window Switch - Driver 2 - S52 Outside Rearview Mirror Switch 3 - A9A Outside Rearview Mirror - Driver 4 - P19G Speaker - Left Front Front Passenger Door Components Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 8863 1 - A9B Outside Rearview Mirror - Passenger 2 - S79P Window Switch - Passenger 3 - M74P Window Motor - Passenger 4 - P19U Speaker - Right Front Left Rear Passenger Side Door Components Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 8864 1 - B27LR Door Handle Switch - Left Rear 2 - S79LR Window Switch - Left Rear 3 - M74LR Window Motor - Left Right Rear Passenger Side Door Components Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 8865 1 - S79RR Window Switch - Right Rear 2 - B27RR Door Handle Switch - Right Rear 3 - M74RR Window Motor - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 8866 Power Window Switch: Diagrams Component Connector End Views S79D Window Switch - Driver (AEC) S79D Window Switch - Driver (AXG) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 8867 S79LR Window Switch - Left Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 8868 S79P Window Switch - Passenger Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 8869 S79RR Window Switch - Right Rear Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 8870 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Multifunction Switch Replacement Power Window Switch: Service and Repair Front Side Door Window and Multifunction Switch Replacement Front Side Door Window and Multifunction Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Multifunction Switch Replacement > Page 8873 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement Rear Side Door Window Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Multifunction Switch Replacement > Page 8874 Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Right Side Front Side Door Window Switch Replacement - Right Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Multifunction Switch Replacement > Page 8875 Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Left Side Front Side Door Window Switch Replacement - Left Side Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 8885 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 8886 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 8887 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 8893 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 8894 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 8895 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Other Service Bulletins for Back Window Glass: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Corner Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Front Corner Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Front Door Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Page 8913 Front Door Window Glass: Service and Repair Front Side Door Window Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Quarter Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair Rear Door Window Glass Weatherstrip: Service and Repair Rear Side Door Window Channel Insulator Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Windshield Moulding / Trim: > 09-08-110-008C > Oct > 10 > Body Driver/Passenger Windshield Pillar Moulding Loose Windshield Moulding / Trim: Customer Interest Body - Driver/Passenger Windshield Pillar Moulding Loose TECHNICAL Bulletin No.: 09-08-110-008C Date: October 14, 2010 Subject: Driver and/or Passenger Side Windshield Pillar Garnish Molding Loose, Gap at Top (Install New Fasteners) Models: 2010-2011 Buick LaCrosse 2008-2011 Cadillac CTS, CTS Sport Wagon, DTS 2008-2011 Chevrolet Captiva Sport, Express 2009-2011 Chevrolet Cruze 2008-2011 GMC Savana 2008-2010 Saturn VUE 2009-2011 Daewoo Lacetti Supercede: This bulletin is being revised to update the model information and parts ordering information. Please discard Corporate Bulletin Number 09-08-110-008B (Section 08 - Body and Accessories). Condition Some customers may comment that the driver and/or passenger side windshield garnish molding is loose, has a gap at the top or is falling off. Cause This condition may be caused by the garnish molding retaining clips not fully engaging or not being replaced at a previous service event. The tether clip is a "one time only" use clip. The clip is not designed for multiple cycles of engaging and releasing. Caution Whenever the windshield side garnish molding is removed or replaced, the upper retaining clip and tether must be replaced with a new service retainer clip. Failure to replace the clip may cause the windshield side garnish molding to not fit or function as designed. Do not reuse the old clip - it is a one time only use design. Do not separate the two halves of the service retainer clip. Correction Important Do not replace the windshield garnish molding assembly if it is not affected. The upper tether fastener is available as a service part. Replace only the fastener as instructed in the bulletin procedure. Use the following steps to install the new service garnish molding upper retaining clip. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Windshield Moulding / Trim: > 09-08-110-008C > Oct > 10 > Body Driver/Passenger Windshield Pillar Moulding Loose > Page 8938 2. Remove the windshield side garnish molding by inserting your fingers between the top of the garnish molding and the headliner. Pull gently to release the clip as shown. 3. With the tether clip open and attached to the body, disengage the clip from the garnish molding. 4. Slide the garnish molding upward to release the molding from the top of the instrument panel. 5. Remove the molding from the vehicle. 6. Depress the tab holding the tether to the metal retainer and remove the tether. 7. Grip the metal retainer with a pair of needle nose pliers as shown. 8. Using a small screwdriver in the hole in the clip, release the inner tab on the metal retainer. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Windshield Moulding / Trim: > 09-08-110-008C > Oct > 10 > Body Driver/Passenger Windshield Pillar Moulding Loose > Page 8939 9. Twisting the clip with the needle nose pliers will help access the tabs. Use a small screwdriver to release to two outer tabs on the metal retainer and remove the retainer from the vehicle. 10. Insert the new service retaining clip into the garnish molding. Ensure the clip is fully seated into the molding. 11. Insert the lower mounting tabs into the top of the instrument panel. No gap should be present between the molding and the top of the instrument panel. 12. Insert the retaining clip into the body and ensure that the clips are fully seated. Inspect the upper molding area and verify that there is no gap at the headliner. 13. Enable SIR system. Refer to SIR Disabling and Enabling in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Moulding / Trim: > 09-08-110-008C > Oct > 10 > Body - Driver/Passenger Windshield Pillar Moulding Loose Windshield Moulding / Trim: All Technical Service Bulletins Body - Driver/Passenger Windshield Pillar Moulding Loose TECHNICAL Bulletin No.: 09-08-110-008C Date: October 14, 2010 Subject: Driver and/or Passenger Side Windshield Pillar Garnish Molding Loose, Gap at Top (Install New Fasteners) Models: 2010-2011 Buick LaCrosse 2008-2011 Cadillac CTS, CTS Sport Wagon, DTS 2008-2011 Chevrolet Captiva Sport, Express 2009-2011 Chevrolet Cruze 2008-2011 GMC Savana 2008-2010 Saturn VUE 2009-2011 Daewoo Lacetti Supercede: This bulletin is being revised to update the model information and parts ordering information. Please discard Corporate Bulletin Number 09-08-110-008B (Section 08 - Body and Accessories). Condition Some customers may comment that the driver and/or passenger side windshield garnish molding is loose, has a gap at the top or is falling off. Cause This condition may be caused by the garnish molding retaining clips not fully engaging or not being replaced at a previous service event. The tether clip is a "one time only" use clip. The clip is not designed for multiple cycles of engaging and releasing. Caution Whenever the windshield side garnish molding is removed or replaced, the upper retaining clip and tether must be replaced with a new service retainer clip. Failure to replace the clip may cause the windshield side garnish molding to not fit or function as designed. Do not reuse the old clip - it is a one time only use design. Do not separate the two halves of the service retainer clip. Correction Important Do not replace the windshield garnish molding assembly if it is not affected. The upper tether fastener is available as a service part. Replace only the fastener as instructed in the bulletin procedure. Use the following steps to install the new service garnish molding upper retaining clip. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Moulding / Trim: > 09-08-110-008C > Oct > 10 > Body - Driver/Passenger Windshield Pillar Moulding Loose > Page 8945 2. Remove the windshield side garnish molding by inserting your fingers between the top of the garnish molding and the headliner. Pull gently to release the clip as shown. 3. With the tether clip open and attached to the body, disengage the clip from the garnish molding. 4. Slide the garnish molding upward to release the molding from the top of the instrument panel. 5. Remove the molding from the vehicle. 6. Depress the tab holding the tether to the metal retainer and remove the tether. 7. Grip the metal retainer with a pair of needle nose pliers as shown. 8. Using a small screwdriver in the hole in the clip, release the inner tab on the metal retainer. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Moulding / Trim: > 09-08-110-008C > Oct > 10 > Body - Driver/Passenger Windshield Pillar Moulding Loose > Page 8946 9. Twisting the clip with the needle nose pliers will help access the tabs. Use a small screwdriver to release to two outer tabs on the metal retainer and remove the retainer from the vehicle. 10. Insert the new service retaining clip into the garnish molding. Ensure the clip is fully seated into the molding. 11. Insert the lower mounting tabs into the top of the instrument panel. No gap should be present between the molding and the top of the instrument panel. 12. Insert the retaining clip into the body and ensure that the clips are fully seated. Inspect the upper molding area and verify that there is no gap at the headliner. 13. Enable SIR system. Refer to SIR Disabling and Enabling in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Rain Sensor > Component Information > Locations Rain Sensor: Locations Passenger Compartment/Roof Component Views Roof/Headliner Components 1 - B160 Windshield Temperature and Inside Moisture Sensor 2 - K84 Remote Function Receiver Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Rain Sensor > Component Information > Locations > Page 8951 Rain Sensor: Diagrams Component Connector End Views B160 Windshield Temperature and Inside Moisture Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations Windshield Washer Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 8956 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 8957 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 8958 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 8962 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 8963 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 8964 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Locations Rain Sensor: Locations Passenger Compartment/Roof Component Views Roof/Headliner Components 1 - B160 Windshield Temperature and Inside Moisture Sensor 2 - K84 Remote Function Receiver Module Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Locations > Page 8969 Rain Sensor: Diagrams Component Connector End Views B160 Windshield Temperature and Inside Moisture Sensor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Windshield Washer Switch: Diagrams Component Connector End Views S80 Window Wiper/Washer Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 8973 Windshield Washer Switch: Service and Repair Windshield Wiper and Washer Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Wiper Switch: Diagrams Component Connector End Views S80 Window Wiper/Washer Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 8977 Wiper Switch: Service and Repair Windshield Wiper and Washer Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations Windshield Washer Pump: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 8981 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 8982 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 8983 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 8984 Windshield Washer Pump: Diagrams Component Connector End Views G24 Windshield Washer Pump Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Windshield Washer Pump Replacement Windshield Washer Pump: Service and Repair Windshield Washer Pump Replacement Windshield Washer Pump Replacement Removal Procedure 1. Remove the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair). 2. Disconnect the washer pump electrical connector (1). 3. Disconnect the washer pump hose (2) from the washer pump (3). 4. Using a small flat-bladed tool, remove the washer pump from the washer solvent container (5). 5. Drain the windshield washer solvent into a clean suitable container. 6. Using a small flat-bladed tool, remove the washer pump terminal seal (4) from the washer solvent container (1). Installation Procedure 1. Position the washer pump terminal seal (4) to the washer solvent container (5), pressing in until fully seated. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Windshield Washer Pump Replacement > Page 8987 2. Using full strength windshield washer solvent as a lubricant on the terminal seal, position the washer pump (3) to the washer solvent container (5) pressing in until fully seated. 3. Connect the washer pump electrical connector (1). 4. Connect the washer pump hose (2) to the washer pump (5). 5. Install the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair). 6. Fill the washer solvent container with washer solvent. 7. Inspect the washer system for proper operation. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Windshield Washer Pump Replacement > Page 8988 Windshield Washer Pump: Service and Repair Windshield Washer Pump Seal Replacement Windshield Washer Pump Seal Replacement Removal Procedure 1. Open the hood. 2. Remove the windshield washer pump. Refer to Windshield Washer Pump Replacement (See: Windshield Washer Pump Replacement) 3. Using a small flat-bladed tool, remove the washer pump terminal seal (1) from the washer solvent container (2). Installation Procedure 1. Position the washer pump terminal seal (1) to the washer solvent container (2), pressing in until fully seated. 2. Install the windshield washer pump. Refer to Windshield Washer Pump Replacement (See: Windshield Washer Pump Replacement) 3. Close the hood. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations Windshield Washer Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 8992 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 8993 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 8994 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Windshield Washer Solvent Container Filler Tube Replacement Windshield Washer Reservoir: Service and Repair Windshield Washer Solvent Container Filler Tube Replacement Windshield Washer Solvent Container Filler Tube Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Windshield Washer Solvent Container Filler Tube Replacement > Page 8999 Windshield Washer Reservoir: Service and Repair Windshield Washer Solvent Container Grommet Replacement Windshield Washer Solvent Container Grommet Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Windshield Washer Solvent Container Filler Tube Replacement > Page 9000 Windshield Washer Reservoir: Service and Repair Windshield Washer Solvent Container Replacement Windshield Washer Solvent Container Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair > Windshield Washer Nozzle Hose Replacement Windshield Washer Spray Nozzle: Service and Repair Windshield Washer Nozzle Hose Replacement Windshield Washer Nozzle Hose Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair > Windshield Washer Nozzle Hose Replacement > Page 9005 Windshield Washer Spray Nozzle: Service and Repair Windshield Washer Nozzle Replacement Windshield Washer Nozzle Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Windshield Washer Switch: Diagrams Component Connector End Views S80 Window Wiper/Washer Switch Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 9009 Windshield Washer Switch: Service and Repair Windshield Wiper and Washer Switch Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments Wiper Arm: Adjustments Windshield Wiper Arm Adjustment Measuring point for windscreen wiper arms: Upper edge of water deflector (rubber lip) to wiper arm attachment point. Note: Position the wiper arm to the basic setting. 1. Driver side (a) approximately 6.5 cm (2.6 in) 2. Passenger side (b) approximately 8.5 cm (3.3 in). Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments > Page 9013 Wiper Arm: Service and Repair Windshield Wiper Arm Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance Wiper Blade: Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance > Page 9018 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Procedures Wiper Blade: Procedures Wiper Blade Element Cleaning Lift each blade assembly off of the windshield and clean the element with a cloth saturated with full strength washer solvent. Then rinse the blade assemblies with clear water. Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Procedures > Page 9021 Wiper Blade: Removal and Replacement Windshield Wiper Blade Replacement (Complete Assembly) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair Wiper Gear Box: Service and Repair Windshield Wiper Transmission Replacement (Left Hand Drive) Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations Wiper Motor: Locations Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components 1 of 2 1 - M75 Windshield Wiper Motor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 9028 Wiper Motor: Diagrams Component Connector End Views M75 Windshield Wiper Motor Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 9029 Wiper Motor: Service and Repair Windshield Wiper Motor Replacement Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Electrical Center Identification Views X50A Fuse Block - Underhood Label Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 9033 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 9034 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 9035 Chevrolet Cruze Workshop Manual (L4-1.4L Turbo (2011)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Wiper Switch: Diagrams Component Connector End Views S80 Window Wiper/Washer Switch